Vibro-Acoustics Analysis for Tool Wear Monitoring During the Turning Operation

Detecting and monitoring of wear on cutting tools is essential in metal-cutting processes as excessive wear led to deteriorate machined surfaces and dimensional distortions in the manufactured components. To address this issue, various research endeavors have focused on the development of tool condition monitoring systems. These systems aim to accurately identify and track the wear of cutting tools, enabling timely interventions and maintenance to minimize production defects and associated expenses. This paper presents an effective tool wear monitoring technique by utilizing vibro-acoustic signature analysis. It employs the cutting tool vibration signals and the audible sound emitted during the machining operation. Based on the analysis of vibro-acoustic signals conducted in both the time and frequency domains, it was observed that certain components of the measured signals exhibited a strong correlation with the accumulated wear on the cutting tool. Furthermore, this technique may also be utilized to predict the tool wear at various cutting environments.