Evaluation of correlation between vibration signal features and three-dimensional finite element simulations to predict cutting tool wear in turning operation

Abstract

This article presents the correlation of vibration signal feature, that is, displacement due to vibration (microns) during the machining and three-dimensional finite element simulations in tool wear monitoring of a metal turning operation. Machining of AISI 1040 has been carried on using an uncoated inserts and online vibration signals acquired using a laser Doppler vibrometer. The measured tool wear forms correlate to features in the vibration signals in frequency domains. Analyses of the results suggested that the vibration signals’ features are effective for use in cutting tool wear monitoring and wear qualification. Present work demonstrates the three-dimensional finite element analysis to predict the workpiece displacements in feed direction and corresponding tool wear with the help of induced vibrations in face turning under dry machining conditions. Vibration-assisted turning model is developed and validated by comparing the simulation results with experimental results. In this research, three-dimensional finite element modelling and simulation issues for vibration-assisted turning are explored in detail. Machine dynamic effects are taken into account to predict the outcomes such as tool wear displacements and chip formation. The model can be implemented in an online tool wear monitoring system which predicts the actual state of tool wear in real time by correlating displacement variations during the machining. The correlation between the displacement due to vibration and flank wear has been evaluated through three-dimensional finite element modelling and simulation. Comparisons of simulations with experimental results demonstrate their predictive capability. From the results, useful conclusions may be drawn, and it can be stated that the proposed models can be used for industrial application.