Abstract
A unique technique is developed for on-line prediction of the tool flank wear in turning using the spindle speed change. A mathematical model is presented for the approach. The speed sensing element is an optical encoder mounted on the spindle shaft and interfaced to an IBM compatible microcomputer employing custom designed electronics. The changes in spindle speed are compensated for lathe transmission ratio, electrical configuration of the the lathe's motor, and the torque speed relationship of the machine. Using the surface response methodology (which reduces the number of cutting sessions required for accurate results), a series of cutting tests are performed with various combinations of cutting speed, feedrate, depth of cut and material hardness. Predictions from the model correlate well with actual flank wear measurements.
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