Abstract
In the last years, hard-to-machine nickel-based alloys have been widely employed in the aerospace industry for their properties of high strength, excellent resistance to corrosion and oxidation, and long creep life at elevated temperatures. As the machinability of these materials is quite low due to high cutting forces, high temperature development and strong work hardening, during machining the cutting tool conditions tend to rapidly deteriorate. Thus, tool health monitoring systems are highly desired to improve tool life and increase productivity. This research work focuses on tool wear estimation during turning of Inconel 718 using wavelet packet transform (WPT) signal analysis and machine learning paradigms. A multiple sensor monitoring system, based on the detection of cutting force, acoustic emission and vibration acceleration signals, was employed during experimental turning trials. The detected sensor signals were subjected to WPT decomposition to extract diverse signal features. The most relevant features were then selected, using correlation measurements, in order to be utilized in artificial neural network based machine learning paradigms for tool wear estimation.
Highlights
In modern machining processes, tool wear estimation is a crucial requirement to prevent machine tool failure and to produce parts with the required high quality
4-element sensor fusion feature patter vectors (FPVs) associated to the three cutting force components and the AERMS (Fig. 11)
A Pearson’s coefficient algorithm was adopted to select the wavelet packet transform (WPT) signal features most correlated with the tool wear level in order to reduce the high dimensionality of the obtained WPT features
Summary
Tool wear estimation is a crucial requirement to prevent machine tool failure and to produce parts with the required high quality. The notable increase in the demand for materials with high strength and temperature resistivity in aerospace and gas turbine industries has led to an extensive use of nickel-based alloys. Inconel 718 is a nickel-based alloy largely utilized to manufacture parts of nuclear reactors, gas turbines, rocket motors, spacecraft, pumps, tooling systems, etc. It combines corrosion resistance and high strength with outstanding weldability, including resistance to post-weld cracking. The machinability of Inconel 718 faces challenges in terms of high cutting forces and high temperature growth, built-up edge formation, strong work hardening, and rapid tool wear development [5, 6]
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