Tool flank wears estimation by simplified SVD on emitted sound signals

Abstract

A non disruptive Monitoring of tool flank wear is a prudent way in the Production process without affecting the throughput. The machining process which involves the tool wear condition inspection without stopping the process has to be done for this. A simple method is proposed through this paper with a novelty of reducing the processing time by sampling method to find the degree of wear of tool flank by closely analyzing a small portion of the sound signal emitted while the turning process captured and in progress. In this work an aluminium portion was used as a primary material on which the carbide material is used as the cutting edge. A uniform Cutting speed is maintained throughout the experiments. The constant feed rate and fixed cutting depth were maintained were as the flank wear assigned as floating. Recordings were done for the emitted sound signals when the turning process was in progress using a fresh tool (0 flank wear) then with another carbide tool with slight wear (0.2–0.25 mm) and finally with the same process but with a severely warned tool bit (0.4mm and above). These recordings were done using a high position microphone in an interleaved way. Individual analysis of the sound signals using Singular Value Decomposition (SVD) is done on pieces of recorded sound waves. A good correlation was formed with the increase in flank wear of the tools and the SVD values found for the pieces of sound waves irrespective of temporal intervals. Hence it can be decided that tool wear monitoring of flank while turning was in progress in small intervals by utilizing SVD features on such emitted sound signal is a prudent and significantly simple method and proved using iterative experiments.