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A review of indirect tool condition monitoring systems and decision‐making methods in turning: Critical analysis and trends
Scopus
Open Access Toplam 267 atıf DOI
The complex structure of turning aggravates obtaining the desired results in terms of tool wear and surface roughness. The existence of high temperature and pressure make difficult to reach and observe the cutting area. In‐direct tool condition, monitoring systems provide tracking the condition of cutting tool via several released or converted energy types, namely, heat, acoustic emis-sion, vibration, cutting forces and motor current. Tool wear inevitably progresses during metal cutting and has a relationship with these energy types. Indirect tool condition monitoring systems use sensors situated around the cutting area to state the wear condition of the cutting tool without in-tervention to cutting zone. In this study, sensors mostly used in indirect tool condition monitoring systems and their correlations between tool wear are reviewed to summarize the literature survey in this field for the last two decades. The reviews about tool condition monitoring systems in turning are very limited, and relationship between measured variables such as tool wear and vibration re-quire a detailed analysis. In this work, the main aim is to discuss the effect of sensorial data on tool wear by considering previous published papers. As a computer aided electronic and mechanical support system, tool condition monitoring paves the way for machining industry and the future and development of Industry 4.0.
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Determination of machinability metrics of AISI 5140 steel for gear manufacturing using different cooling/lubrication conditions
Scopus
Havuzumuzda Open Access 29 atıf almış
AISI 5140 steel is mostly used in gear manufacturing for variety of industries. Those gears can be manufactured via casting, powder metallurgy or forging techniques. Nevertheless, machining (via turning and milling processes) remains the most common manufacturing method to fabricate them. Milling of gears made from 5140 steel can be challenging due to the excessive energy consumption, rapid tool wear and poor surface finish. Therefore, traditional and environmentally friendly coolants are usually applied during machining to improve the surface finish and prolong tool life. The current study aims to investigate machinability performance of 5140 steel under different cooling/lubrication conditions. Several machinability metrics were investigated and analyzed (surface roughness, cutting temperature, tool wear, chip morphology, and energy consumption). Milling tests were performed under different cutting speeds (75 and 100 m/min), different feed rates (0.15 and 0.2 mm/rev) and dry, minimum quantity lubrication (MQL), and cryogenic liquid cooling/lubrication conditions (dry, MQL and cryo-LN2). The results showed that using Cryo-LN2 cooling/lubrication tended to improve all the investigated machinability metrics compared to dry condition. The surface roughness was reduced by approximately 54%, while the cutting temperature was reduced by 87%. Similarity, the cutting tool flank wear was reduced by 20% thus energy consumption was minimized by 15%. The current study shows the importance of cryogenic machining in industry for difficult to cut materials.
Atıf Yapan Makale Bilgileri
Kurumlar (5)
Bingöl Üniversitesi
Bingol, Turkey
Inönü Üniversitesi
Malatya, Turkey
Lovely Professional University
Phagwara, India
South Ural State University
Chelyabinsk, Russian Federation
University of Portsmouth
Portsmouth, United Kingdom