Abstract
The acting thermo-mechanical load during metal cutting and the resulting tool wear influence significantly the surface integrity and thus thecomponent functionality. Therefore, in-process measurement of such process variables is a key strategic approach for monitoring of cutting operations. This manuscript presents a new experimental setup implementing a digital microscope camera and different sophisticated sensors for an automatic measurement of cutting force, temperature, tool wear, acoustic emission and magnetic Barkhausen noise during turning operations. To check the proposed test setup, turning tests on drive shafts from steel 42CrMo4 are performed. The analysis and correlation of the measured process variables with surface integrity parameters show the suitability and robustness of the developed experimental setup.
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