Abstract
FEM chip formation simulations and machining tests of orthogonal cutting were undertaken in order to investigate the influence of cutting speed and tool wear on cutting force, chip segmentation frequency, and residual stress state for Ti-6Al-4V. In addition, acoustic emissions, measured by a piezoelectric sensor adapted to the tool shank, were analyzed to extract chip segmentation frequency in-process using time-frequency representations and periodograms. Results show the capability of robust chip segmentation frequency measuring. The hypothesis of compensating the negative effect of tool wear on the component’s residual stress state by means of targeted adjustment of process parameters can be derived.
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