On Line Condition Monitoring of Tool Wear Machining Process for Titanium Alloys

Abstract

Turning is one of the most necessary operations in the machining and manufacturing newlineindustries. The quality of products as well as work pieces is easily predicted by analysing the newlinesurface roughness characteristic of the product or work piece. The surface roughness newlinecharacteristic value depends on a number of process parameters. During turning, a huge newlinenumber of process parameters are directly or indirectly involved in the wear mechanism of newlinetool inserts. newlineThe blunt tool not only affects the quality of the workpiece but also the overall newlineperformance of the machine. Here, condition monitoring of the health structure of the tool newlineinsert is needed to get information regarding the behaviour of the tool from time to time. A newlineonline tool wear condition monitoring systems exhibit many advantages over traditional newlinemachining processes (turning operations). newlineIn this study, experiments were conducted on a titanium alloy to estimate the newlineperformance of the CBN insert in the hard-turning process under dry environmental newlineconditions. The three process parameters at three different levels are considered, such as newlinecutting speed in rpm, depth of cut in mm, and feed rate in mm per sec, for process newlineoptimization. The response variables collected were acoustic emission, tool wear, and surface newlineroughness. In addition, more emphasis is placed on the AE results to observe their potential to newlineprovide necessary real-time knowledge and tool wear monitoring capability during the turning newlineof titanium alloy under dry environmental conditions