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<p>Excessive tool vibration during milling operations can lead to poor surface finishes and accelerated tool wear, making it a critical factor in machining performance. This study investigates the time-domain vibration signals captured during the milling of pre-hardened mold steel, utilizing a solid carbide cutting tool coated with Cr-doped TiAlN (Varacon Plus). The research analyzes the impact of various cutting conditions, including three cutting speeds and two feed per tooth values, on tool vibration intensity and wear. The findings indicate a strong correlation between vibration amplitude and tool wear; the lowest vibrations corresponded with lower wear levels, while higher vibrations were associated with significant wear. Abrupt increases in vibration were linked to drastic tool failures, and progressive wear contributed to gradual instability. Additionally, cutting conditions, particularly feed per tooth, were shown to substantially affect tool stability, indicating that they influence wear more significantly than vibration alone. This study underscores the importance of vibration analysis as an effective monitoring technique for tool condition and stability during milling processes, providing valuable insights for the optimization of machining parameters and tool design strategies to enhance performance and longevity.</p>

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Examining vibration signals in the time domain during W 1.2711 steel milling to correlate tool wear with cutting parameters

  • 期刊论文

  • 发表日期：

    2026年1月6日

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  • A. F. S. Mesquita,
  • H. M. Lopes,
  • F. J. G. Silva,
  • N. P. V. Sebbe,
  • I. Iglesias,
  • R. C. M. Sales-Contini

摘要

Excessive tool vibration during milling operations can lead to poor surface finishes and accelerated tool wear, making it a critical factor in machining performance. This study investigates the time-domain vibration signals captured during the milling of pre-hardened mold steel, utilizing a solid carbide cutting tool coated with Cr-doped TiAlN (Varacon Plus). The research analyzes the impact of various cutting conditions, including three cutting speeds and two feed per tooth values, on tool vibration intensity and wear. The findings indicate a strong correlation between vibration amplitude and tool wear; the lowest vibrations corresponded with lower wear levels, while higher vibrations were associated with significant wear. Abrupt increases in vibration were linked to drastic tool failures, and progressive wear contributed to gradual instability. Additionally, cutting conditions, particularly feed per tooth, were shown to substantially affect tool stability, indicating that they influence wear more significantly than vibration alone. This study underscores the importance of vibration analysis as an effective monitoring technique for tool condition and stability during milling processes, providing valuable insights for the optimization of machining parameters and tool design strategies to enhance performance and longevity.