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Tool Wear Inspection of Polycrystalline Cubic Boron Nitride Inserts

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Special Topics in Structural Dynamics, Volume 5

Abstract

In industry, highly frequent inspection of tooling used to machine safety critical components is common place. Worn or damaged tools produce undesirable surface finishes leading often to early failure of the part due to fatigue crack growth. In the development stages of polycrystalline boron nitride tools, the tool wear inspection technique is an off-line run-to-failure method. This approach interrupts the cutting process intermittently, to measure the tool wear using optical and scanning microscopy. This method is time consuming and expensive, causing bottlenecks in production. The overall aim in industry is to develop an on-line, automated system capable of informing the operator of the tool’s imminent failure. This paper focuses on treating this process as a preventative maintenance problem by studying whether acoustic emission can be used as an indirect measurement of tool wear at any given time. Acoustic emission measurements taken from the machining process of face turning are investigated here. Basic analysis in the frequency domain using principle component analysis reveals a number of interesting insights into the process. Relationships between the sharpness of the tool and the magnitude of the frequencies suggests promising link between acoustic emission and tool wear.

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Acknowledgements

The research facilities of Element Six Ltd. in Oxford funded this work and also provided the machine, workpieces and tools used in this experiment. This work was also part funded by the EPSRC. The Advanced Manufacturing Research Centre (AMRC) in Rotherham extended a lot of help and guidance throughout this experiment.

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Authors and Affiliations

  1. Dynamics Research Group, Department of Mechanical Engineering, University of Sheffield, Sheffield, UK

    Chandula Wickramarachchi

  2. Industrial Doctorate Centre in Machining Science, Rotherham, UK

    Chandula Wickramarachchi

  3. Advanced Manufacturing Research Centre, Rotherham, UK

    T. E. McLeay & S. Ayvar-Soberanis

  4. Element Six Global Innovation Centre, Didcot, UK

    W. Leahy

  5. Dynamics Research Group, Department of Mechanical Engineering, University of Sheffield, Sheffield, UK

    E. J. Cross

Authors
  1. Chandula Wickramarachchi
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  2. T. E. McLeay
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  3. S. Ayvar-Soberanis
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  4. W. Leahy
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  5. E. J. Cross
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Corresponding author

Correspondence to Chandula Wickramarachchi .

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Editors and Affiliations

  1. University of Sheffield, Sheffield, United Kingdom

    Nikolaos Dervilis

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© 2019 The Society for Experimental Mechanics, Inc.

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Wickramarachchi, C., McLeay, T.E., Ayvar-Soberanis, S., Leahy, W., Cross, E.J. (2019). Tool Wear Inspection of Polycrystalline Cubic Boron Nitride Inserts. In: Dervilis, N. (eds) Special Topics in Structural Dynamics, Volume 5. Conference Proceedings of the Society for Experimental Mechanics Series. Springer, Cham. https://doi.org/10.1007/978-3-319-75390-4_24

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  • DOI: https://doi.org/10.1007/978-3-319-75390-4_24

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  • Publisher Name: Springer, Cham

  • Print ISBN: 978-3-319-75389-8

  • Online ISBN: 978-3-319-75390-4

  • eBook Packages: EngineeringEngineering (R0)

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