Evaluation of correlation between vibration signal features and three-dimensional finite element simulations to predict cutting tool wear in turning operation
Evaluation of correlation between vibration signal features and three-dimensional finite element simulations to predict cutting tool wear in turning operation
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DOI：
10.1177/0954405414554018
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发表时间：
2016-02
期刊：
影响因子：
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通讯作者：
B. S. Prasad;M. P. Babu;Y. R. Reddy
中科院分区：
文献类型：
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作者：
B. S. Prasad;M. P. Babu;Y. R. Reddy
本文介绍了振动信号特征的相关性，即，由于振动（微米）在加工和三维有限元模拟金属车削操作的刀具磨损监测中的位移。使用未涂覆的刀片和使用激光多普勒测振仪采集的在线振动信号对AISI 1040进行了加工。测量的刀具磨损形式与频域中的振动信号中的特征相关。分析结果表明，振动信号的特征是有效的，用于刀具磨损监测和磨损合格。目前的工作演示了三维有限元分析，预测在进给方向上的工件位移和相应的刀具磨损的帮助下，在干加工条件下的端面车削诱导振动。建立了振动辅助车削模型，并将仿真结果与实验结果进行了对比验证。本研究针对振动辅助车削之三维有限元建模与模拟问题进行详细探讨。机床动态效应被考虑在内，以预测的结果，如刀具磨损位移和切屑形成。该模型可以在刀具磨损在线监测系统中实现，该系统通过关联加工过程中的位移变化来真实的预测刀具磨损的实际状态。通过三维有限元建模和仿真，已经评估了由于振动和后刀面磨损的位移之间的相关性。模拟与实验结果的比较表明其预测能力。从结果中可以得出有用的结论，可以说，所提出的模型可以用于工业应用。
This article presents the correlation of vibration signal feature, that is, displacement due to vibration (microns) during the machining and three-dimensional finite element simulations in tool wear monitoring of a metal turning operation. Machining of AISI 1040 has been carried on using an uncoated inserts and online vibration signals acquired using a laser Doppler vibrometer. The measured tool wear forms correlate to features in the vibration signals in frequency domains. Analyses of the results suggested that the vibration signals’ features are effective for use in cutting tool wear monitoring and wear qualification. Present work demonstrates the three-dimensional finite element analysis to predict the workpiece displacements in feed direction and corresponding tool wear with the help of induced vibrations in face turning under dry machining conditions. Vibration-assisted turning model is developed and validated by comparing the simulation results with experimental results. In this research, three-dimensional finite element modelling and simulation issues for vibration-assisted turning are explored in detail. Machine dynamic effects are taken into account to predict the outcomes such as tool wear displacements and chip formation. The model can be implemented in an online tool wear monitoring system which predicts the actual state of tool wear in real time by correlating displacement variations during the machining. The correlation between the displacement due to vibration and flank wear has been evaluated through three-dimensional finite element modelling and simulation. Comparisons of simulations with experimental results demonstrate their predictive capability. From the results, useful conclusions may be drawn, and it can be stated that the proposed models can be used for industrial application.