Multi-Sensor Intelligent System for On-Line and Real-Time Moneitoring Tool Cutting State in FMS

The principle and the constitution of an intelligent system for on-line and real-time montitoring tool cutting state were discussed and a synthetic sensors schedule combined a new type fluid acoustic emission sensor (AE) with motor current sensor was presented. The parallel communication between control system of machine tools, the monitoring intelligent system,and several decision-making systems for identifying tool cutting state was established It can auto - matically select the sensor way ,monitoring mode and identifying method in machining process- ing so as to build a successful and effective intelligent system for on -line and real-time moni- toring cutting tool states in FMS.

Prediction of Wearing of Cutting Tools Using Real Time Machining Parameters and Temperature Using Rayleigh-Ham Method

Wear of cutting tools is a big concern for industrial manufacturers, because of their acquisition cost as well as the impact on the production lines when they are unavailable. Law of wear is very important in determining cutting tools lifespan, but most of the existing models don’t take into account the cutting temperature. In this work, the theoretical and experimental results of a dynamic study of metal machining against cutting temperature of a treated steel of grade S235JR with a high-speed steel tool are provided. This study is based on the analysis of two complementary approaches, an experimental approach with the measurement of the temperature and on the other hand, an approach using modeling. Based on unifactorial and multifactorial tests (speed of cut, feed, and depth of cut), this study allowed the highlighting of the influence of the cutting temperature on the machining time. To achieve this objective, two specific approaches have been selected. The first was to measure the temperature of the cutting tool and the second was to determine the wear law using Rayleigh-Ham dimensional analysis method. This study permitted the determination of a law that integrates the cutting temperature in the calculations of the lifespan of the tools during machining.

INFLUENCE OF COLD NITROGEN GAS AND OIL MIST IN MACHINING NICKEL-BASE K424 ALLOY WITH CERAMIC CUTTING TOOLS

The role of cold nitrogen gas and oil mist on tool wear and surface roughness is investigated in turning the K424 nickel-base super alloy with Sialon and SiC whisker-reinforced alumina ceramic tools. A new cooling system is developed and used to lower the temperature of the compressed nitrogen gas. Experiments are performed in three different cooling/lubrication modes, i.e. the dry cutting, the cold nitrogen gas （CNG）, and the cold nitrogen gas and oil mist （CNGOM）. Experimental results show that the depth-of-cut notching severely limits the tool life in all the cooling/lubrication modes. Compared with the dry cutting, the use of CNG and CNGOMcan yield higher wear rate of depth-of-cut notching and worse surface finish.

Comparison of TiAlN, AlCrN, and AlCrN/TiAlN coatings for cutting-tool applications

Monolayer and bilayer coatings of TiAlN, AlCrN, and AlCrN/TiAlN were deposited onto tungsten carbide inserts using the plasma enhanced physical vapor deposition process. The microstructures of the coatings were characterized using scanning electron microscopy （SEM） and atomic force microscopy （AFM）. The SEM micrographs revealed that the AlrN and AlCrN/TiAlN coatings were uniform and highly dense and contained only a limited number of microvoids. The TiAIN coating was non-uniform and highly porous and contained more micro droplets. The hardness and scratch resistance of the specimens were measured using a nanoindentation tester and scratch tester, respectively. Different phases formed in the coatings were analyzed by X-ray diffraction （XRD）. The AlCrN/TiAlN coating exhibited a higher hardness （32.75 GPa）, a higher Young＇s modulus （561.97 GPa）, and superior scratch resistance （LcN = 46 N） compared to conventional coatings such as TiAlN, A1CrN, and TiN.

Smart Cutting Tools and Smart Machining: Development Approaches, and Their Implementation and Application Perspectives

Smart machining has tremendous potential and is becoming one of new generation high value precision manufacturing technologies in line with the advance of Industry 4.0 concepts. This paper presents some innovative design concepts and, in particular, the development of four types of smart cutting tools, including a force-based smart cutting tool, a temperature-based internally-cooled cutting tool, a fast tool servo （FTS） and smart collets for ultra- precision and micro manufacturing purposes. Implemen- tation and application perspectives of these smart cutting tools are explored and discussed particularly for smart machining against a number of industrial application requirements. They are contamination-free machining, machining of tool-wear-prone Si-based infra-red devices and medical applications, high speed micro milling and micro drilling, etc. Furthermore, implementation tech- niques are presented focusing on： （a） plug-and-produce design principle and the associated smart control algo- rithms, （b） piezoelectric film and surface acoustic wave transducers to measure cutting forces in process, （c） critical cutting temperature control in real-time machining, （d） in- process calibration through machining trials, （e） FE-based design and analysis of smart cutting tools, and （f） applica- tion exemplars on adaptive smart machining.

Tool Wear and Its Effect on Surface Roughness in Diamond Cutting of Glass Soda-lime

For the technology of diamond cutting of optical glass, the high tool wear rate is a main reason for hindering the practical application of this technology. Many researches on diamond tool wear in glass cutting rest on wear phenomenon describing simply without analyzing the genesis of wear phenomenon and interpreting the formation process of tool wear in mechanics. For in depth understanding of the tool wear and its effect on surface roughness in diamond cutting of glass, experiments of diamond turning with cutting distance increasing gradually are carried out on soda-lime glass. The wear morphology of rake face and flank face, the corresponding surface features of workpiece and the surface roughness, and the material compositions of flank wear area are detected. Experimental results indicate that the flank wear is predominant in diamond cutting glass and the flank wear land is characterized by micro-grooves, some smooth crater on the rake face is also seen. The surface roughness begins to increase rapidly, when the cutting mode changes from ductile to brittle for the aggravation of tool wear with the cutting distance over 150 m. The main mechanisms of inducing tool wear in diamond cutting of glass are diffusion, mechanical friction, thermo-chemical action and abrasive wear. The proposed research makes analysis and research from wear mechanism on the tool wear and its effect on surface roughness in diamond cutting of glass, and provides theoretical basis for minimizing the tool wear in diamond cutting brittle materials, such as optical glass.

Relationship Between Thermal Shock Behavior and Cutting Performance of a Functionally Gradient Ceramic Tool

Based on the deep understanding of the requirements of cutting conditions on ceramic tools, a design model for functionally gradient ceramic tool materials with symmetrical composition distribution was presented in this paper, according to which an Al 2O 3-TiC functionally gradient ceramic tool material FG-1 was synthesized by powder-laminating and uniaxially hot-pressing technique. The thermal shock resistance of the Al 2O 3-TiC functionally gradient ceramics FG-1 was evaluated by water quenching and subsequent three-point bending tests of flexural strength diminution. Comparisons were made with results from parallel experiments conducted using a homogeneous Al 2O 3-TiC ceramics. Functionally gradient ceramics exhibited higher retained strength under all thermal shock temperature differences compared to homogeneous ceramics, indicating the higher thermal shock resistance. The experimental results were supported by the calculation of transient thermal stress field. The cutting performance of the Al 2O 3-TiC functionally gradient ceramic tool FG-1 was also investigated in rough turning the cylindrical surface of exhaust valve of diesel engine in comparison with that of a common Al 2O 3-TiC ceramic tool LT55. The results indicated that the tool life of FG-1 increased by 50 percent over that of LT55. Tool life of LT55 was mainly controlled by thermal shock cracking which was accompanied by mechanical shock. While tool life of FG-1 was mainly controlled by mechanical fatigue crack extension rather than thermal shock cracking, revealing the less thermal shock susceptibility of functionally gradient ceramics than that of common ceramics.

Synergistically Toughening Effect of SiC Whiskers and Nanoparticles in Al_2O_3-based Composite Ceramic Cutting Tool Material

In recent decades, many additives with different characteristics have been applied to strengthen and toughen Al2O3-based ceramic cutting tool materials. Among them, SiC whiskers and SiC nanoparticles showed excellent performance in improving the material properties. While no attempts have been made to add SiC whiskers and SiC nanoparticles together into the ceramic matrix and the synergistically toughening effects of them have not been studied. An Al2O3-SiCw-SiC np advanced ceramic cutting tool material is fabricated by adding both one-dimensional SiC whiskers and zero-dimensional SiC nanoparticles into the Al2O3 matrix with an effective dispersing and mixing process. The composites with 25 vol% SiC whiskers and 25 vol% SiC nanoparticles alone are also investegated for comparison purposes. Results show that the Al2O3-SiCw-SiCnp composite with both 20 vo1% SiC whiskers and 5 vol% SiC nanoparticles additives have much improved mechanical properties. The flexural strength of Al2O3-SiCw-SiCnp is 730＋ 95 MPa and fracture toughness is 5.6 ± 0.6 MPa.m1/2. The toughening and strengthening mechanisms of SiC whiskers and nanoparticles are studied when they are added either individually or in combination. It is indicated that when SiC whiskers and nanoparticles are added together, the grains are further refined and homogenized, so that the microstructure and fracture mode ratio is modified. The SiC nanoparticles are found helpful to enhance the toughening effects of the SiC whiskers. The proposed research helps to enrich the types of ceramic cutting tool and is benefit to expand the application range of ceramic cutting tool.

Cutting Temperature and Tool Wear of Hard Turning Hardened Bearing Steel

A study was undertaken to investigate the performan ce of PCBN tool in the finish turning GCr15 bearing steel with different hardness between 30～64 HRC. The natural thermocouple was used to measure the cutting tem p erature, tool life and cutting temperature were investigated and compared. The m aterial can be heated by this instrument which using low voltage and high elec trical current, while PCBN can’t be heated by electrifying directly, so the ke ntanium layer coating over the PCBN is heated, so the PCBN is heated and its th ermoelectric property is got by this method. [TPP129,+60mm88mm,Y,PZ#] Fig.1 Effect of cutting depth and workpiec hardness on. the cutting temperatureThe objective was to determine the influence of the workpiece hardness on change s in cutting temperature and tool wear characterize. It can be found from Fig.1 that the cutting temperature show an increasing tendency with the improvement of workpiece hardness within the cutting speed scope when the workpiece hardness i s under HRC50. And on the other hand, it is found that the cutting temperature s how the downtrend with the improvement of workpiece hardness when the workpiece hardness is over HRC50. According to experimental results, the critical hard ness when turning hardened GCr15 bearing steel with PCBN tool is about HRC50. Th e wear causes of PCBN tool have been found out through taking photos on the micr o-shape of PCBN poly-laminate initial surface as well as face and flank of wea r tool and analysis on chemical elements. It is discovered that the PCBN tools a re not suitable for cutting the workpiece at nearly critical hardness, because n ear the critical hardness, PCBN wear at the highest speed. For researching the w ear rule of PCBN tool, the tool wear experiments have been carried on by using b earing steel GCr15 at hardness HRC40 and HRC60 with changing cutting speed. The indexes of tool life equations is gained under two kinds of conditions w hich are bigger than 0.6, so the effects of cutting speed on the PCBN tool are m uch less than that of carbide tool and ceramic tool.

Cutting Performance and Mechanism of RE Carbide Tools

The research of rare earth elements (RE), added into cemented carbide tools, is one of the recent developments of new types of tool materials in China. Systematic experiments about RE carbides YG8R. (K30), YT14R (P20) and, YW1R (M10) were made to study on the cutting performance in comparison with non-RE carbides YG8, YT14 and YW1. The cutting experiments were as follows: tool life, cutting force, tool-chip friction coefficient and interrupted machining. The action of RE on the carbide materials and the cutting mechanism of the RE carbide tools in the cutting process were verified with the aid of SEM and energy spectrum analysis. Experimental results show that the RE carbide tools have a good overall performance.

Performance evaluation of minimum quantity lubrication by vege-table oil in terms of cutting force,cutting zone temperature,tool wear,job dimension and surface finish in turning AISI-1060 steel

In all machining processes, tool wear is a natural phenomenon and it leads to tool failure. The growing demands for high productivity of machining need use of high cutting velocity and feed rate. Such machining inherently produces high cutting temperature, which not only reduces tool life but also impairs the product quality. Metal cutting fluid changes the performance of machining operations because of their lubrication, cooling and chip flushing functions, but the use of cutting fluid has become more problematic in terms of both employee health and environmental pollution. The minimization of cutting fluid also leads to economical benefits by way of saving lubricant costs and workpiece/tool/machine cleaning cycle time. The concept of minimum quantity lubrication (MQL) has been suggested since a decade ago as a means of addressing the issues of environmental intru- siveness and occupational hazards associated with the airborne cutting fluid particles on factory shop floors. This paper deals with experimental investigation on the role of MQL by vegetable oil on cutting temperature, tool wear, surface roughness and dimen- sional deviation in turning AISI-1060 steel at industrial speed-feed combinations by uncoated carbide insert. The encouraging results include significant reduction in tool wear rate, dimensional inaccuracy and surface roughness by MQL mainly through reduction in the cutting zone temperature and favorable change in the chip-tool and work-tool interaction.

Adhesion Wear on Tool Rake and Flank Faces in Dry Cutting of Ti-6Al-4V

Titanium alloys are very chemically reactive and,therefore,have a tendency to weld to the cutting tool during machining.The deterioration in the tool life caused by adhesion is a serious problem when titanium alloys are cut using carbide tools.The chemical reactivity of titanium alloys with carbide tool materials and their consequent welding by adhesion onto the cutting tool during dry cutting leads to excessive chipping,premature tool failure,and poor surface finish.In the present study,dry turning and milling tests were carried out on Ti-6Al-4V alloys with WC?Co carbide tools.The adhesion on the tool rake and flank face was explored,the adhesive joint interface between the workpiece materials and tools were observed.SEM observation showed that adhesion can be observed both on the rake and the flank face,and was more pronounced in rake face than in flank face.There was evidence of element diffusion from the tool rake face to the adhering layer(vice versa) through the adhesive joint interface,which leads to the tool element loss and microstructure change.While the adhering materials at the flank face can be easily separated from the joint interface owing to the lower temperature and less pressure at the flank face,the adhesive wear attack results in an abrasive wear in the flank face.Moreover,adhesion is more notable in turning than in milling.The proposed research provides references for studying the adhesion between the workpiece materials and the tools,the adhesion mechanisms and their effect on the tool wear.

WEAR AND LIFE OF PCBN TOOLS WHEN DRY-CUTTING BEARING STEEL GCr15

The wear forms and reasons of PCBN tools when dry-cutting bearing steel GCr15are studied systematically. The effect law of the workpiece hardness on PCBN tools is gained andtool wearing with the quickest speed at the workpiece critical hardness is proved. The life equationat two kinds of workpiece hardness demonstrates that the effect of the cutting speed on the PCBNtool life is less than that of carbide tools and ceramic tools.

A critical review on the chemical wear and wear suppression of diamond tools in diamond cutting of ferrous metals

Diamond tools play a critical role in ultra-precision machining due to their excellent physical and mechanical material properties,such as that cutting edge can be sharpened to nanoscale accuracy.However,abrasive chemical reactions between diamond and non-diamond-machinable metal elements,including Fe,Cr,Ti,Ni,etc,can cause excessive tool wear in diamond cutting of such metals and most of their alloys.This paper reviews the latest achievements in the chemical wear and wear suppression methods for diamond tools in cutting of ferrous metals.The focus will be on the wear mechanism of diamond tools,and the typical wear reduction methods for diamond cutting of ferrous metals,including ultrasonic vibration cutting,cryogenic cutting,surface nitridation and plasma assisted cutting,etc.Relevant commercially available devices are introduced as well.Furthermore,future research trends in diamond tool wear suppression are discussed and examined.

MULTI-SCALE AND MULTI-PHASE NANOCOMPOSITE CERAMIC TOOLS AND CUTTING PERFORMANCE

An advanced ceramic cutting tool material Al2O3/TiC/TiN （LTN） is developed by incorporation and dispersion of micro-scale TiC particle and nano-scale TiN particle in alumina matrix. With the optimal dispersing and fabricating technology, this multi-scale and multi-phase nanocomposite ceramic tool material can get both higher flexural strength and fracture toughness than that of A1203/TiC （LZ） ceramic tool material without nano-scale TiN particle, especially the fracture toughness can reach to 7.8 MPa . m^0.5. The nano-scale TiN can lead to the grain fining effect and promote the sintering process to get a higher density. The coexisting transgranular and intergranular fracture mode induced by micro-scale TiC and nano-scale TiN, and the homogeneous and densified microstructure can result in a remarkable strengthening and toughening effect. The cutting performance and wear mechanisms of the advanced multi-scale and multi-phase nanocomposite ceramic cutting tool are researched.

Comparative Study on Tool Fault Diagnosis Methods Using Vibration Signals and Cutting Force Signals by Machine Learning Technique

The state of cutting tool determines the quality of surface produced on the machined parts.A faulty tool produces poor sur face,inaccurate geometry and non-economic production.Thus,it is necessary to monitor tool condition for a.machining process to have superior quality and economic production.In the pre-sent study,fault classification of single point cutting tool for hard turning has been carried out by employing machine learning technique.Cutting force and vibration signals were acquired to monitor tool condition during machining.A set of four tooling conditions namely healthy,worn flank,broken insert and extended tool overhang have been considered for the study.The machine learning technique was applied to both vibration and cutting force signals.Discrete wavelet features of the signals have been extracted using discrete wavelet trans formation(DWT).This transformation represents a large dataset into approximation coeffcients which contain the most useful information of the dataset.Significant features,among features extracted,were selected using J48 decision tree technique.Clas-sification of tool conditions was carried out us ing Naive Bayes algorithm.A 10 fold cross validation was incorporated to test the validity of classifier.A comparison of performance of classifier was made between cutting force and vibration signal to choose the best signal acquisition method in classifying tool fault conditions using machine learning technique.

Advances in micro cutting tool design and fabrication

Microcutting is a precision technology that offers flexible fabrication of microfeatures or complex three-dimensional components with high machining accuracy and superior surface quality.This technology may offer great potential as well as advantageous process capabilities for the machining of hard-to-cut materials,such as tungsten carbide.The geometrical design and dimension of the tool cutting edge is a key factor that determines the size and form accuracy possible in the machined workpiece.Currently,the majority of commercial microtools are scaled-down versions of conventional macrotool designs.This approach does not impart optimal performance due to size effects and associated phenomena.Consequently,in-depth analysis and implementation of microcutting mechanics and fundamentals are required to enable successful industrial adaptation in microtool design and fabrication methods.This paper serves as a review of recent microtool designs,materials,and fabrication methods.Analysis of tool performance is discussed,and new approaches and techniques are examined.Of particular focus is tool wear suppression in the machining of hard materials and associated process parameters,including internal cooling and surface patterning techniques.The review concludes with suggestions for an integrated design and fabrication process chain which can aid industrial microtool manufacture.

Dynamic modeling of ultra-precision fly cutting machine tool and the effect of ambient vibration on its tool tip response

The dynamic performances of an ultra-precision fly cutting machine tool(UFCMT)has a dramatic impact on the quality of ultra-precision machining.In this study,the dynamic model of an UFCMT was established based on the transfer matrix method for multibody systems.In particular,the large-span scale flow field mesh model was created;and the variation in linear and angular stiffness of journal and thrust bearings with respect to film thickness was investigated by adopting the dynamic mesh technique.The dynamic model was proven to be valid by comparing the dynamic characteristics of the machine tool obtained by numerical simulation with the experimental results.In addition,the power spectrum density estimation method was adopted to simulate the statistical ambient vibration excitation by processing the ambient vibration signal measured over a long period of time.Applying it to the dynamic model,the dynamic response of the tool tip under ambient vibration was investigated.The results elucidated that the tool tip response was significantly affected by ambient vibration,and the isolation foundation had a good effect on vibration isolation.

Wear Patterns and Mechanisms of Cutting Tools in High Speed Face Milling

High speed machining has received an important interest because it leads to an increase of productivity and a better workpiece surface quality. However, at high cutting speeds, the tool wear increases dramatically due to the high temperature at the tool-workpiece interface. Tool wear impairs the surface finish and hence the tool life is reduced. That is why an important objective of metal cutting research has been the assessment of tool wear patterns and mechanisms. In this paper, wear performances of PCBN tool, ceramic tool, coated carbide tool and fine-grained carbide tool in high speed face milling were presented when cutting cast iron, 45# tempered carbon steel and 45# hardened carbon steel. Tool wear patterns were examined through a tool-making microscope. The research results showed that tool wear types differed in various matching of materials between cutting tool and workpiece. The dominant wear patterns observed were rake face wear, flank wear, chipping, fracture and breakage. The main wear mechanisms were mechanical friction, adhesion, diffusion and chemical wear promoted by cutting forces and high cutting temperature. Hence, the important considerations of high speed cutting tool materials are high heat-resistance and wear-resistance, chemical stability as well as resistance to failure of coatings. The research results will be great benefit to the design and the selection of tool materials and control of tool wear in high-speed machining processes.

Comparing the Effectiveness of Coatings on Carbide andCermet Cutting Tool Inserts

A series of metal cutting experiments was performed on a CNC lathe to evaluate the performance of various coatings on different tool substrates. The workpiece material was plain medium carbon steel and the cutting tool materials were carbide and cermet inserts coated with various single as well as multilayer coatings. Machining was done under various cutting conditions of speed and feed-rate, and for various durations of Cutting. The output parameters studied were the cutting forces (axial, radial and tangential), the surface roughness of the workpiece, as well as the tool wear (crater and flank wear). From these results, the performances of the various cutting inserts are evaluated and compared. Results show that cutting forces are significantly lower when using coated cermets than when using coated carbides although different coatings on the same substrate also result in different cutting forces. However, there is less difference in the surface roughness of the finished workpiece for the various coatings and substrates.