Tool Condition Monitoring in Microturning of Aluminium Alloy Using Multiple Sensors

A. Gopikrishnan; M. Kanthababu; R. Balasubramaniam; Prabhat Ranjan

doi:10.4028/www.scientific.net/AMM.592-594.796

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HomeApplied Mechanics and MaterialsApplied Mechanics and Materials Vols. 592-594Tool Condition Monitoring in Microturning of...

Tool Condition Monitoring in Microturning of Aluminium Alloy Using Multiple Sensors

Abstract:

In the present work, an attempt has been made to monitor the tool condition status during microturning of aluminium alloy (AA 6061) using multiple sensors such as cutting force dynamometer, acoustic emission (AE) and accelerometer. The tool wear (nose wear) is correlated with surface roughness (R_a), chip width, thrust force (F_x), tangential force (F_y), feed force (F_z), AE_RMS and vibration signals. It is observed that R_a, chip width and cutting forces are increased with increase in the tool wear. Among the cutting forces, the tangential force (F_y) is found to be more sensitive to the tool wear status compared to that of the thrust force (F_x) and feed force (F_z). From the signal analysis, it is observed that during machining with good tool condition, the dominant frequency of the AE_RMS and vibration signals are found to be 81 kHz-110 kHz and 2.07 kHz-3.84 kHz respectively, whereas with the worn out tool the dominant frequencies are shifted to higher levels. Chip morphological studies indicated that favourable type of chips are formed upto 40^th minute and unfavourable chips are observed from 41^st minute to 60^th minute.

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Periodical:

Applied Mechanics and Materials (Volumes 592-594)

Pages:

796-800

DOI:

https://doi.org/10.4028/www.scientific.net/AMM.592-594.796

Citation:

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Online since:

July 2014

Authors:

A. Gopikrishnan, M. Kanthababu*, R. Balasubramaniam, Prabhat Ranjan

Keywords:

Accelerometer, Acoustic Emission (AE), Chip Morphology, Cutting Force Dynamometer, Frequency Domain, Microturning, Time Domain

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* - Corresponding Author

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