Non-destructive Evaluation Division, Metallurgy and Materials Group, IGCAR, India; Homi Bhabha National Institute, Kalpakkam, Tamil Nadu 603102, India.
Homi Bhabha National Institute, Kalpakkam, Tamil Nadu 603102, India.
Ultrasonics. 2022 Aug;124:106762. doi: 10.1016/j.ultras.2022.106762. Epub 2022 May 14.
Tool wear leads to dimensional inaccuracy and low surface quality in the workpiece, and unexpected sudden tool failure. Detection of tool wear is essential to enhance the quality of manufacturing components and extend tool life. The present work is aimed to investigate the various damage mechanisms involved in the cutting tool and workpiece during drilling of Al-5%BC composite using acoustic emission technique (AET). The dry drilling experiments were carried out at different spindle speeds and feed rates with high strength steel (HSS) tool. AE time-domain parameters such as count, energy, amplitude and root mean square (RMS) voltage were extracted from the signals and correlated with cutting parameters and tool damage. Fast Fourier transform (FFT) was applied to visualize the frequency components in the AE signals during the drilling process. The wavelet packet transform (WPT) approach was performed to the AE signals to identify and discriminate the various damage mechanism involved in the drilling. The differentiated damage mechanism and their corresponding wavelet energy content were studied. The wavelet energy ratio for decomposed components at different speeds was discussed. The vision measuring microscope was employed to measure the tool wear. The AE features, i.e., AE and wavelet coefficient increases with increasing tool wear. A scanning electron microscope was also utilized to characterize the microstructural damage present in the cutting tool and workpiece.
刀具磨损会导致工件尺寸精度降低和表面质量下降，以及意外的刀具突然失效。检测刀具磨损对于提高制造部件的质量和延长刀具寿命至关重要。本工作旨在研究使用声发射技术（AET）在钻削 Al-5%BC 复合材料时刀具和工件中涉及的各种损坏机制。在不同的主轴转速和进给率下进行了干钻实验，使用高强度钢（HSS）刀具。从信号中提取了声发射时域参数，如计数、能量、幅度和均方根（RMS）电压，并将其与切削参数和刀具损坏相关联。应用快速傅里叶变换（FFT）将声发射信号中的频率分量可视化在钻削过程中。对声发射信号进行了小波包变换（WPT）处理，以识别和区分钻削过程中涉及的各种损坏机制。研究了不同的损伤机制及其相应的小波能量含量。讨论了在不同速度下分解组件的小波能量比。使用视觉测量显微镜测量刀具磨损。随着刀具磨损的增加，声发射特征（即声发射和小波系数）增加。还利用扫描电子显微镜来表征刀具和工件中存在的微观结构损坏。
