Experimental evaluation of flank wear in dry turning from accelerometer data

Abstract

This paper presents an experimental evaluation of cutting tool wear based on vibration signals to study the wear development of the cutting tool insert in order to increase machining performance. To achieve this purpose, tool life tests according to ISO standard 3685 have been performed in turning operation under dry cutting conditions. The wear development was studied for thirty cutting tool inserts selected from the same production batch, and used in strictly identical experimental conditions for a statistical study. The vibration signatures acquired during cutting processes have been analysed and contrasted using three signal processing techniques: statistical, temporal and spectral analysis. Results have shown that the dynamic characteristics of tool vibration changed with cutting tool wear development. Furthermore, this vibration analysis exhibited a strong correlation, during machining, between the evolution of flank wear land and vibration responses.