Analysis of real-time vibration assisted tool condition monitoring in drilling

Abstract

The present work primarily focuses on identifying the presence of drilling tool vibrations during the drilling process. A non-contact vibration transducer laser Doppler vibrometer (LDV) is used as part of this approach. Values of cutting forces and vibration signal features (SFs) with the progression cutting tool wear in dry machining of Ti-6Al-4V and Al7075 are recorded and analysed. This paper presents a modified mathematical model in an attempt to understand tool life under vibratory cutting conditions. Identifying the relationship among tool wear, cutting forces and displacement due to vibration is a critical task in the present study. These results are used to predict the evolution of displacement and tool wear in the experiment. The effect of workpiece movement due to vibration on the tool wear is critically examined. Finally, tool wear is determined by the maximum displacement that can be borne in a process for an efficient tool condition monitoring system. [Submitted 21 January 2017; Accepted 16 March 2018]