Condition monitoring of turning process using infrared thermography technique – An experimental approach

• Published in: Infrared physics & technology 2017-03, Vol.81, p.137-147
• Main Authors: Prasad, Balla Srinivasa, Prabha, K. Aruna, Kumar, P.V.S. Ganesh
• Format: Article
• Language: English
• Subjects: Condition monitoring; Infrared thermography; Multi sensor; Tool wear; Vibrations
• ISSN: 1350-4495; 1879-0275
• DOI: 10.1016/j.infrared.2016.12.023

•In this work both infrared thermography and laser Doppler vibrometer are used to acquire data during turning.•Proposed a strategy for condition monitoring which is based on both ISO-18434-2008 and ISO 10816-3.•Experimental data is validated in real time. In metal cutting machining, major factors that affect the cutting tool life are machine tool vibrations, tool tip/chip temperature and surface roughness along with machining parameters like cutting speed, feed rate, depth of cut, tool geometry, etc., so it becomes important for the manufacturing industry to find the suitable levels of process parameters for obtaining maintaining tool life. Heat generation in cutting was always a main topic to be studied in machining. Recent advancement in signal processing and information technology has resulted in the use of multiple sensors for development of the effective monitoring of tool condition monitoring systems with improved accuracy. From a process improvement point of view, it is definitely more advantageous to proactively monitor quality directly in the process instead of the product, so that the consequences of a defective part can be minimized or even eliminated. In the present work, a real time process monitoring method is explored using multiple sensors. It focuses on the development of a test bed for monitoring the tool condition in turning of AISI 316L steel by using both coated and uncoated carbide inserts. Proposed tool condition monitoring (TCM) is evaluated in the high speed turning using multiple sensors such as Laser Doppler vibrometer and infrared thermography technique. The results indicate the feasibility of using the dominant frequency of the vibration signals for the monitoring of high speed turning operations along with temperatures gradient. A possible correlation is identified in both regular and irregular cutting tool wear. While cutting speed and feed rate proved to be influential parameter on the depicted temperatures and depth of cut to be less influential. Generally, it is observed that lower heat and temperatures are generated when coated inserts are employed. It is found that cutting temperatures are gradually increased as edge wear and deformation developed.