The RMS Characteristics of Acceleration and Force Signals Depending on Tool Wear in Stable Cutting

Abstract

Abstract An analysis of the RMS (Root Mean Square) characteristics of fluctuating force and acceleration signals for a cutting tool engaged in a turning operation in the presence of wear flat on the tool flank is presented in this research. The RMS of acceleration and force signals obtained from experiments in stable cutting is compared with theoretical machining models due to the tool wear effect. The RMS is a measure of the energy, at the tool tip-workpiece interface along the flank, to the random vibration of the cantilever portion of the tool holder. Increasing flank wear results in an increasing stability and decreasing RMS in the thrust direction, dependent upon flank wear-land width. The RMS force and acceleration signals in machining is calculated by frequency band RMS method at the first natural frequency of the cantilever portion of the tool holder in the frequency domain. By reference to experimental evidence, the theoretical predictions show generally good agreement with test results.