Abstract
For monitoring tool wear state of three dimensional turning process under various cutting conditions, a active monitoring method-diagnostic impulse excitation method-was proposed. It was clearly shown that the dynamic characteristics of the impact response of tool vibration, especially, the damping ratio was closely related with flank wear development. In order to separate the damping ratio only concerned on the wear from total damping ratio, the ratio of wear free tool was obtained experimentally and formulated under various cutting conditions and various tool edge geometry. The ratio of wear free tool was shown to be linearly increased with the contact edge length with workpiece, and also with the feed force. The ratio concerned with flank wear may be separately measured using the results of wear free tool. The energy consumption concerned on wear land may be easily obtained using the measured damping ratio under various cutting conditions for various tool geometry with flank wear land. The energy consumption mechanism on flank wear land for various tool geometry and under various cutting conditions was discussed. The consumption was quantitatively obtained, which is caused by interaction between a flank wear land and a machined surface. Through the discussions the relation between the measured damping ratio and the flank wear area was shown. The theoretical relation can give the flank wear development for various tool geometry under various cutting conditions based on only the damping ratio measured.
