Modelling the effect of flank wear on machining thrust stability

Authors: Liang, S.¹; Kwon, Y.²; Chiou, R.³

Source: The International Journal of Advanced Manufacturing Technology, Volume 23, Numbers 11-12, June 2004 , pp. 857-864(8)

Publisher: Springer

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Abstract:

This paper discusses an analytical assessment of the effect of cutting tool flank wear on machining stability along the thrust direction in a turning operation based on an analysis of frequency band root-mean-square (RMS) level of the accelerometer signals. The energy content of machining at the tool-tip/workpiece interface along the flank is represented by the RMS signal level, in comparison to the random vibration of the cantilever portion of the tool holder. The RMS signals measured from a tool-post accelerometer in stable machining with tool wear effect are calculated using the frequency band RMS method at the first natural frequency of the cantilever portion of the tool holder. Increasing flank wear results in increasing stability and decreasing RMS in the thrust direction in machining. For model validation, a series of machining experiments were performed under the condition of various flank wear/land widths, while the RMS signals from a tool-post accelerometer were collected and studied. It was found that theoretical predictions were shown to be in agreement with experimental results.

Document Type: Research article

DOI: http://dx.doi.org/10.1007/s00170-003-1756-1

Affiliations: 1: The Georgia W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332, USA, Email: steven.liang@gatech.edu 2: Department of Mechanical Engineering, Jeonju Technical College, Jeonju, Korea, 3: Applied Engineering Technology, Goodwin College, Drexel University, Philadelphia, PA 19104, USA,

Publication date: 2004-06-01