Please use this identifier to cite or link to this item: http://hdl.handle.net/11455/91321
標題: On-line Ceramic Cutting Tool Flank Wear Monitoring in Hard Turning
硬車削中陶瓷刀具之刀腹磨耗線上監測研究
作者: 朱永哲
Yung-Che Chu
關鍵字: Hard turning
Ceramic tool
Flank wear
Acoustic emission
Cutting force.
硬車削
陶瓷車刀
刀腹磨耗
聲射訊號
切削力
引用: [1] H.K. Tonshoff, C. Arendt, and R.B. Amor, 2000,'Cutting of hardened steel.' CIRP, vol.49, p.p.547-565. [2] Y. K. Chou, C. J. Evans, 1999, 'White layers and thermal modeling of hard turned surfaces', International Journal of Machine Tools & Manufacture, vol.39, p.p.1863- 1881. [3] 林維新,2005,'以 CBN 刀具精密切削硬化模具鋼 SKD11 之研究',2005 模 具技術與論文發表會,頁 1-8,台北,6 月 10 日。 [4] E. Aslan, 2005, 'Experimental investigation of cutting tool performance in high speed cutting of hardened X210 Cr12 cold-work tool steel (62HRc)', Materials and Design, vol.26, p.p.21-27. [5] J. Bhaskaran, M. Murugan, N. Balashanmugam, M. Chellamalai, 2012, 'Monitoring of hard turning using acoustic emission signal', Journal of Mechanical Science and Technology, vol.26, p.p.609~615. [6] D. Shi, N. N. Gindy, 2007, 'Development of an online machining process monitoring system: Application in hard turning', Sensors and Actuators, vol.135, p.p.405-414. [7] J. M. Zhou, M. Andersson, J. E. Stahl, 2003, 'The monitoring of flank wear on the CBN tool in the hard turning process', The International Journal of Advanced Manufacturing Technology, vol.22, p.p.697-702. [8] C. Scheffer, H. Kratz, P. S. Heyns, F. Klocke, 2003, 'Development of a tool wear- monitoring system for hard turning', International Journal of Machine Tools & Manufacture', vol.43, p.p.973-985. [9] B. Fnides, H. Aouici, M. A. Yallese, 2008,'Cutting forces and surface roughness in hard turning of hot work steel X38CrMoV5-1 using mixed ceramic', MECHANIKA, vol.70, p.p73-78. [10] A. Al-Habaibeh, A.Al-Azmi, 2010, 'The Application of Force and Acoustic Emission Sensors for Detecting Tool Damage in Turning Processes,' Key Engineering Materials, pp.381-384. [11] C. Chungchoo, D. Saini, 2002, 'A computer algorithm for flank and crater wear estimation in CNC turning operations,' Int J Mach Tool Manuf 42, pp.1465-1477. [12] M. T. Telsang, Katu, 2004, 'Condition Monitoring of Single-Point Cutting Tool Using Acoustic Emission Technique,' Journal of the Institution of Engineers(India), pp.77-81. [13] S. Dolinsek , J. Kopac, 1999, 'Acoustic emission signals for tool wear identification,' Wear, pp. 295–303. [14] E. M. Rubio, R. Teti, 2006, 'Advanced signal processing in acoustic emission monitoring systems for machining technology,' Intelligent Production Machines and Systems, pp.1-6. [15] E. Dimla, Snr. Dimla, 2000, 'Sensor signals for tool-wear monitoring in metal cutting operations—a review of methods,' International Journal of Machine Tools & Manufacture, pp.1073–1098. [16] K. Jemielniak, T. Urbański, J. Kossakowska, S. Bombiński, 2012, 'Tool condition monitoring based on numerous signal features,' Int J Adv Manuf Technol, pp.73– 81. [17] E. P. Degarmo, JT. Black, R. A. Kohser, 2003, MATERIALS AND PROCESSES IN MANUFACTURING, John Wiley & Sons, Inc. [18] 洪良德,2001,切削刀具學,四版,高立圖書有限公司。 [19] N. R. Dhar, S. Islam, Md. Kamruzzaman, S. Paul, 'Wear behavior of uncoated
摘要: Hard turning is that turning the harden steels as final processes or fine machining to replace grinding processes. In the cutting process, tool wear cause surface roughness and dimensional precision getting worse. Ceramic tool with high hardness, high strength, wear resistance, chemical stability and cheaper price, but it's sensitive to processing condition. It's important that monitoring the tool wear of ceramic tool in hard turning. This research studies the ceramic tool flank wear on-line monitioing in hard turning. The ceramic insert A65 used in hard turning experiment to turn the die steel SKD61 which harden to HRC60 by heat treatment. The acoustic emission sensor and the dynamometer using to obtain the acoustic emission signal and cutting force on sharp tool, VB 0.05mm, VB 0.1mm and VB 0.15mm of ceramic tool in hard turning. Then analyze and studies the relationship between the flank wear of ceramic tool, cutting force and acoustic emission. The result of experiment that the cutting force in x-axis, y-axis and z-axis will increase when the flank wear of ceramic tool increase. On the other hand, the acoustic emission energy decrease when the flank wear of ceramic tool from sharp tool increase to VB 0.1mm. Then the acoustic emission energy sharply increase when the flank wear from VB 0.1mm to VB 0.15mm. Using FFT to transform the acoustic emission signal from time domain to frequency domain. In frequency domain, the trend of most of frequency are the same as time domain of acoustic emission signal. However, in some particular frequency range (nearby 170 kHz or 185 kHz), the acoustic emission energy increase when the flank wear increase from sharp tool to VB 0.15mm.
硬車削(Hard turning)是指把淬硬鋼的車削做為最後加工或精加工,以取代磨 削加工的加工方式。切削加工的過程中,刀具磨耗會使得加工出來的成品表面品 質及尺寸精度下降。陶瓷車刀具有高硬度、高強度、耐磨性佳、化學穩定性好等 特性,且價格較為低廉,但對加工條件敏感。故對於使用陶瓷車刀進行硬車削加 工時,對其刀具磨耗的監測相當重要。 本研究將使用陶瓷車刀片 A65 對 SKD61 模具鋼(HRc60)進行硬車削加工,同 時架設聲射感測器及動力計以擷取聲射訊號和切削力訊號,在不拆卸陶瓷車刀片 的情況下使用移動式顯微鏡觀察其刀腹磨耗,在到達目標刀腹磨耗值時進行加工 中之切削力與聲射訊號的擷取,之後分析並探討陶瓷車刀之刀腹磨耗對聲射訊號 以及切削力變化的關係。 實驗結果表示當刀腹磨耗上升時,X、Y、Z 三軸方向切削力也會隨之上升。 而在聲射訊號方面則是在未磨耗刀具至刀腹磨耗為 0.1mm 時,聲射訊號能量是下 降的趨勢,但在刀腹磨耗 0.1 至 0.15mm 時則聲射訊號能量有上升的趨勢。將時 域聲射訊號進行快速傅立葉轉換(FFT)處理後,從頻域方面觀察的結果,在大多數 的頻率下聲射訊號能量的變化仍與時域的趨勢相同,卻只有在特定的頻率區段 (170kHz 或 185kHz)附近,聲射訊號能量會隨著刀腹磨耗的提升而有上升的趨勢。
URI: http://hdl.handle.net/11455/91321
文章公開時間: 2017-07-16
Appears in Collections:機械工程學系所

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