Acoustic emission monitoring of tool wear during the face milling of steels and aluminium alloys using a fibre optic sensor. Part 2: Frequency analysis
Free accessResearch articleFirst published online April, 1997
Acoustic emission monitoring of tool wear during the face milling of steels and aluminium alloys using a fibre optic sensor. Part 2: Frequency analysis
This paper describes the application of acoustic emission (AE) frequency analysis to cutting tool wear monitoring in finish milling operations. AE detection was achieved using a fibre optic interferometer which, unlike conventional piezoelectric transducers, allows absolute measurements of the frequency content of the signals, generated during face milling of various steels and aluminium alloys, to be made. A model detailing the expected variations in AE mean frequency with various forms of tool wear in the different processes is presented and is validated by the practical set of tool wear tests using the fibre optic interferometer.
DornfeldD. A.Kannatey-AsibuE.Acoustic emission during orthogonal metal cutting. Int. J. Mech. Sci., 1980, 22, 285–296.
2.
DieiE. N.DornfeldD. A.Acoustic emission from the face milling process–the effects of process variables. Trans. ASME, J. Engng for Industry, May 1987, 109, 92–99.
3.
DieiE. N.DornfeldD. A.Acoustic emission sensing of tool wear in face milling. Trans. ASME, J. Engng for Industry, August 1987, 109, 234–240.
4.
CarolanT. A.KiddS. R.HandD. P.WilcoxS. J.WilkinsonP.BartonJ. S.JonesJ. D. C.ReubenR. L.Acoustic emission monitoring of tool wear during the face milling of steels and aluminium alloys using a fibre optic sensor. Part 1: Energy analysis. Proc. Instn Mech. Engrs, Part B, 1997, 211(B4), 299–309.
5.
RangwalaS.DornfeldD. A.A study of acoustic emission generated during orthogonal metal cutting. Int. J. Mech. Sci., 1991, 33(6), 471–487 and 489–499.
6.
DinizA. E.LiuJ. J.DornfeldD. A.Correlating tool life, tool wear and surface roughness by monitoring acoustic emission in finish turning. Wear, 1992, 152, 395–407.
7.
McBrideR.CarolanT. A.BartonJ. S.WilcoxS. J.BorthwickW. K. D.JonesJ. D. C.Detection of acoustic emission in cutting processes by fibre optic interferometry. Measmt Sci. Technol., 1993, 4, 1122–1129.
8.
GillisP.P.Dislocation motions and acoustic emissions. In Acoustic Emission, ASTM STP 505, 1972, pp. 20–29 (American Society for Testing and Materials, Philadelphia, Pennsylvania).
9.
FleischmannP.LakestaniF.BabouxJ. C.RoubyD.Analyse spectrale et energÃtique d'une source ultrasonore en mouvement. Mater. Sci. Engng, 1977, 29, 205–212.
10.
RoubyD.FleischmannP.DuvergierC.An acoustic emission source model for both continuous and burst-type emission analysis–I. Theory. Phil. Mag., 1983, 47(5), 671–687.
11.
RoubyD.FleischmannP.DuvergierC.An acoustic emission source model for both continuous and burst-type emission analysis–II. Experiments. Phil. Mag., 1983, 47(5), 689–705.
12.
ShawM. C.Metal Cutting Principles, 1984 (Oxford University Press).
13.
HastingsW. F.OxleyP. L. B.Predicting tool life from fundamental work material properties and cutting conditions. CIRP Ann., 1976, 25(1), 33–38.
14.
HuR. S.MathewP.OxleyP. L. B.YoungH. T.Allowing for end cutting effects in predicting forces in bar turning with oblique machining conditions. Proc. Instn Mech. Engrs, Part C, 1986, 200(C2), 89–99.
15.
HeipleC. R.CarpenterS. H.ChristiansenS. S.Fracture of boron particles in 2219 aluminium as a known acoustic emission source. Acta Metall. Mater., 1990, 38(4), 611–618.
16.
MortimerD. B.Fibreloop reflectors. J. Lightwave Technol., 1988, 6(7), 1217–1224.
17.
JacksonD. A.PriestR.DandridgeA.TvetenA. B.Elimination of drift in single-mode optical fiber interferometer using a piezoelectrically stretched coiled fiber. Appl. Optics, 1980, 19, 2926–2929.
BucharJ.BilekZ.DusekF.Mechanical Behaviour of Metals at Extremely High Strain Rates, 1986 (Trans Tech Publications, Switzerland).
20.
CarolanT. A.WilkinsonP.HandD. P.BartonJ. S.JonesJ. C. D.ReubenR. L.Assessment of tool wear in milling using acoustic emission detected by a fibre optic interferometer. Trans. ASME, J. Mfg Sci. Engng, 1996, 118, 428–433.
