Abstract
Tool condition monitoring is one of the important aspects in machining process to improve tool life. It comprises three important steps namely machining data acquisition, data analysis and decision making. Vibration in metal cutting has direct impact on the tool life as well as surface roughness. The present study focused on measurement of vibration during the machining process. Data acquisition is made by using various types of sensors. A wide variety of technologies like contact and non contact sensors have been used for real time data acquisition of tool or work piece vibrations. Research works carried out by many authors is highlighted in measurement of cutting tool and machine tool vibrations using different sensors. Influence of various input parameters like tool geometry, feed, speed and depth of cut on the magnitude of vibrations is discussed. Influence of vibration on surface roughness, tool life and power consumption is reviewed. Three dimensional vibration measurement with single Laser Doppler Vibrometer is also covered for precise analysis of vibration.
Highlights
Tool Condition Monitoring (TCM) is an essential requirement in advanced manufacturing process to monitor the performance of cutting tools
Vibration measurement can be carried by non-contact type sensor like Laser Doppler Vibrometer (LDV) (EWINS,1984; VENKATRAO et al, 2013; BALAJI et al, 2018)
Vibration is one of the important factor that plays a vital role on the performance of cutting tool as well as tool life, surface quality of finished component and power consumption
Summary
Tool Condition Monitoring (TCM) is an essential requirement in advanced manufacturing process to monitor the performance of cutting tools. Milling, drilling and boring processes are difficult machining processes when compared to other machining processes In these processes, tool vibration induced by cutting forces influences the tool life and surface quality of component. In some machining process like milling, turning and drilling etc., vibrations alters the machining characteristics such as surface roughness, dimensional accuracy and tool life. Chang (2001) reported that the tool life and surface finish are strongly influenced by frequency and amplitude of vibration He concluded that the tool geometry plays an important role in the generation of tool vibration. Self-excited vibrations are caused by chatter and mutual interaction between the insufficient rigidity of machine tool This leads to disturbances in cutting zones. Measurement of vibration and sensors used in the measurement are reviewed
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