Detecting tool breakage in turning aisi 1050 steel using coated and uncoated cutting tools

Abstract

Tool life and condition monitoring systems can be used effectively in cutting processes. Since no exact and reliable mathematical models exist for the cutting process which are able to predict tool wear, tool breakage, cutting temperature and forces, the development of tool condition monitoring systems are highly requested by industry, especially in recent years. The purpose of this research is to develop a tool condition monitoring and a real-time tool life detection system in turning processes. The software and hardware generated for this research is based on the characteristic variations of the cutting forces. When a tool wears or breaks, cutting forces increase slightly right after the tool breakage and then decrease sharply. The change of cutting forces can itself be a good indicator to detect the tool failure. The experimental set-up developed in this research consists of a dynamometer, a pre-amplifier, an A/D converter, and a personal computer. The workpiece material is AISI 1050 steel and the tool material is coated and uncoated tungsten carbide (ISO P25). The type of insert that is used is DNMG 150608. No cutting fluid was used during the turning operations. The performance of the system has been tested experimentally for certain machining conditions and the experimental results showed that the system was being successful in tool breakage detection.