INTRODUCTION

the high forces and temperature devoloped in machining is harmful for both the tool and the
workpiece.when suface finish and form accuracy is the primary goal ,any wear on the tool is
directly transfered on workpiece.also,it increases the power consumption and efficiency of machine
decreases.Knowing when to sharpen or replace the tool can save money and time.

Definition

Tool Life :it is defined as the length of cutting time that the tool can be used.tool can fail in
machining in following ways-
1.Fracture Failure:due to excessive cutting force at tool point.
2.Temperature Failure:due to softening of tool material at elevated temperatures.
3.Gradual Wearing:causes loss of tool shape,reduction in cutting efficiency.

Tool Wear:Tool wear describes the gradual failure of cutting tools due to regular operation. It is a
term often associated with tipped tools, tool bits, or drill bits that are used with machine tool.

It is of two types:
1.Crater Wear:It consists of concave section on rake surface,formed due to sliding of chip against
surface.The crater can be measured either by its area or depth.
2.Flank Wear: It occurs on the flank of tooldue to rubbing between newly generated suface and
adjacent flank surface.It is measured by the width of wear band.
The mechanism that cause wearing are adhesion,abrasion,chemical reaction,plastic deformation etc.

Fig. Microscopic View of Flank Wear Area

Tool life and tool wear rate depend on work material,speed,feed and depth of cut.

Evaluation of tool wear and tool life

There are a variety of methods used in industry and academia to measure tool wear
and determine the tool life in a particular machining operation. Some methods can be described as
direct tool wear measurements. These methods quantify the size and shape of the wear scar on the
tool. Direct tool wear measurements are generally performed off-line, but some direct methods such
as radioactive, pneumatic, electrical resistance, and optical sensing techniques, can be performed
on-line as well. Some of the most widely used and effective methods for measuring tool wear are
optical methods. High power microscopes and scanning electron microscopes (SEMs) are used to
closely examine the wear on the cutting edge. Wear can be quantified by comparing the image of a
worn tool with the image of a new tool.
In indirect methods we measure by monitoring other machining parameters. These parameters
correlate fairly well to tool wear and are generally much easier to measure. Methods for indirect
tool wear monitoring include measuring changes in cutting forces, workpiece dimensions, surface
finish, cutting temperature, vibration, and acoustic emission. Interpretation of data acquired during
vibration monitoring, acoustic emission monitoring, force monitoring, and other forms of on-line
tool wear measurement is many times performed through the use of fuzzy logic and fuzzy pattern
recognition .

Experiment Proposal

Tools and Measuring Instruments:

Turning Dynamometer
　Turning dynamometers may be strain gauge or piezoelectric type and may be
of one, two or three dimensions capable to monitor all of PX, PY and PZ.
For ease of manufacture and low cost, strain gauge type turning
dynamometers are widely used and preferably of 2 – D (dimension) for
simpler construction, lower cost and ability to provide almost all the desired
force values.
Design and construction of a strain – gauge type 2 – D turning dynamometer
are shown schematically in Fig. 10.8 and photographically in Fig. 10.9 Two full
bridges comprising four live strain gauges are provided for PZ and PX
channels which are connected with the strain measuring bridge for detection
and measurement of strain in terms of voltage which provides the magnitude
of the cutting forces through calibration. Fig. 10.10 pictorially shows use of 3 –
D turning dynamometer having piezoelectric transducers inside.
For our experiment we will use Kistler dynamometer type 9265 B with data acquisition system.

Split Box
　
Sensor signals from the dynamometer are sent to a split box which functions to branch the incoming signals
into three separate channels for the three orthogonal force components. The output from the split box is sent
in to three charge amplifiers through a 3-way BNC cable.

Charge Amplifier
　
Besides the dynamometer, a three component force measurement system also needs three charge
amplifiers, which convert the dynamometer charge signals into output voltages proportional to the forces
sustained.

Filter
　
Some of the signals sent in by the dynamometer are undesired signals or noise generated by the metal
removal process and the other surrounding media. These signals fall in the range of frequency which is
distinctly different from that of the measured force signals frequency band. The filter removes these
unwanted noises from the signal and sends it to a sensor interface module. The 3 charge amplifiers and the
filter are integrated into a single instrument called a Dual mode amplifier [Company: KISTLER] with a rating
of 100 KHz (Sr. # C180250)

Sensor Interface Module

　
Metalmax Instrument, model # SIM 2, Sr. # 119. Sensor Interface Module provides four channels of voltage
source input signals. The force signals from filter is fed into this sensor interface module and it functions,
along-with the data acquisition card, to process the signals in the format which can further be fed in the
computer.

Data Acquisition Card (DAQ)

　
The signal from the sensor interface module is sent to a DAQ through a special DAQ cable [National
Institute, Sr. # 1835698-01]. The DAQ acquires the sensor signals and converts into a data format which can
be fed into a personal computer. The DAQ is a type- AI-16 E-4 with 16 inputs, 500Ks/s with a 12 bit
multifunction input/output system. The Data Signals from DAQ are fed into a PC which displays the result in
a graphical format. This display is the real time monitoring of the cutting forces’ behavior.

Methodology

We will obtain cutting forces component FY, feed force component FX and radial or thrust force
component FZ from the turning dynamometer. The equation which we will use for evaluating tool
wear is following
Y = - 0.02657 + 0.00015062(A) + 0.00002506(R) - 0.00001899(T) - 0.00000467(A*R) -7.45E-07(A*T) +
0.00000336(R*T) + 0.00000141(A2) + 0.00000198(R2) - 5.79E-07(T2) + 0.00000543(S) - 0.56406(F) +
0.03419(F*A) -0.09894(F*R) + 0.01621(F*T)

Y = Maximum tool wear

X1 = Axial component of cutting force (A)
 X2 = Radial component of cutting force (R)

X3 = Tangential component of cutting force (T)

X4 = Spindle Speed (S)

X5 = Feed (F)

Interaction Terms of Force Components = (A*R), (A*T), (R*T)

Interaction Terms of Feed and Force Components = (F*A), (F*R), (F*T)
Quadratic Terms of Force Components = (A2), (R2), (T2)
The above equation is based on experimental data sets obtained from experiment conducted in Icams lab in
University of Cincinnati and TechSolve Inc.

Experimental Setup

Procedure
we will fix the workpiece in between the headstock and tailstock.The dynamomter and all the above
equipments are fixed like experimental setup.tool wear will be calculated and displayed on PC using a
software.The software will take FX,FY&FZ as input and using above formula it will calculate wear.
For general purpose we will use 0.05 mm of flank wear as our cut-off.The temperature sensor will give the
temperature which will decide the softening point of the tool.if the point will come before the FW cutoff then
the tool will fail earlier.

Reference
1.Tool wear measurement in turning using force ratio.S. K. Choudhury and K. K. Kishore
“International Journal of Machine Tools and Manufacture Volume 40, Issue 6, May 2000, Pages 899-
909”
2.Instrumentation of tool wear evaluation. Steven W. Henry
3.Investigations by Icams lab in University of Cincinnati and TechSolve Inc.