On-line Monitoring of Cutting Temperature by Remote Thermocouple Sensing Technique
Date Issued
2012
Date
2012
Author(s)
Chu, Wei-Ying
Abstract
Monitoring of cutting tool condition is very important for the efficient operation machine. The purpose of monitoring is to increase the precision and quality of the products. A great deal of research revealed that signal detection of acoustic emissions, cutting forces, cutting vibrations and cutting temperature, are often used as indicators in on-line monitoring. Monitoring cutting temperature always increases the cost of products, which is unacceptable in the industry. For instance, the most common method is to drill a hole close to the cutting edge of cutting tool and insert a thermocouple. However, this would increase the cost of machining operations. Another way is to use an infrared thermometer, but chips often obstruct the view of cutting edge and the equipment is very expensive. However, measuring the cutting temperature is a very effective for monitoring the status of inserts. Once the tool is worn, its temperature rises. The purpose of this study is to increase the feasibility of cutting temperature monitoring.
In this study, the objective of this research is to use remote thermocouple sensing technology to overcome this issue and develop a system of on-line monitoring of cutting temperature. By measuring the temperature with a thermocouple placed under the inserts, we can estimate the temperature of the edge of the cutting tool with a proper mathematic model. Therefore, we will be able to monitor the temperature of the cutting tools. The advantage of this method is that temperature measurements are not affected by the material properties of the workpiece. And the need for expensive equipment like dynamometer is eliminated. To estimate cutting edge temperature, the only information required is the material properties of the cutting tool, the contact length and the remote temperature.
The experimental results show that the non-cutting tests are within 5% error and cutting experiments within 2% error. Steady-state temperature can be estimated in 5 seconds. Finally, errors in the cutting test when the cutting speed changes from 140 m/min to 320 m/min are 8%.
Subjects
Cutting temperature
On-line monitoring
Type
thesis
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