Manufacturing Technology Today

P. Thangavel ¹, V. Selladurai ²

Affiliations
1 Dept, of Mech. Engg., C.I. E.T, Narasipuram Post, Coimbatore - 641 109, IN
2 Dept, of Mech. Engineering, C.I.T, Coimbatore - 641 014, IN

Abstract

A reliable and sensitive technique to monitor the tool wear without interrupting the process became a crucial issue for realization of the modern manufacturing concepts without human resources at machining centers. A proper oniine cutting tool condition monitoring system is essential for deciding when change the tool. This paper outlines a neural network based tool condition monitoring system for cutting tool flank wear. The cutting tests were performed on mild steel using HSS tool and on-line cutting forces data was acquired with a cutting force dynamometer. Simultaneously flank wear was measured using a toolmakers microscope and the processed data were fed to a Back Propagation Neural Network (BPNN). The developed system then was tested to predict flank wear for various cutting conditions. The output of the neural network is capable of accurate tool wear prediction for the range it had been trained but the accuracy deteriorated as the cutting conditions were changed significantly.

Full Text

     

T. Alwarsamy ¹, V. Selladurai ², P. Thangavel ², M. Murugan ³, A. Gopal Das ³

Affiliations
1 GCT, CBE, IN
2 CIT, CBE, IN
3 GCT Campus, Coimbatore-641013, IN

Abstract

In the turning operation, chatter or vibration is a frequent problem, which affects the surface finish and tool life. In all cutting operations like turning, boring and milling vibrations are induced due to the deformation of the workpiece, this implies economical disadvantage. The main objective of the proposed work is to design damped tool holder for existing machine tools with low cost fabrication techniques. In this investigation, improvement of the damping capability of boring tool and suppression of chatter vibration using lead damper and Impact damper are analyzed. The lead damper Inertia mass of the boring tool has been Increased to suppress the chatter vibration. In impact damper kinetic energy of free mass is dissipated. Finite element analysis is performed to study dynamic behavior of composite tool holder, the effects of overhang length of boring tool with lead damper, and the effects of impact damper in boring tool was investigated.

Full Text