36 CHAPTER 3 EXPERIMENTAL SET-UP AND PROCEDURE 3.1 GENERAL Tool wear monitoring continuous to be a major area of concern in machining. In order to produce quality products at reasonable cost tool condition monitoring becomes an important study for all the researchers. To monitor the tool wear during machining process an experimental study has been carried out using acoustic emission technique (AET). Further these experimental results are used to train Artificial Neural Network (ANN) and Adaptive Neuro Fuzzy Inference system (ANFIS). The details of the experimental setup, procedure, AET, ANN and ANFIS are discussed in this chapter. 3.2 EXPERIMENTAL SET-UP Figure 3.1 shows the schematic of the experimental setup developed in this research work. A Banka make, 5.0 HP, all – geared centre lathe was used for machining. C45 steel of 270 BHN was used as the work material. TK35- CNMG 12 04 08 carbide coated cutting tool insert and PCLNR – 16 16 K12 Tool holder were used. The tool was coated with one layer of TiC and TiN, and thirteen layers of AlON using chemical vapour deposition (CVD) process for better stress propagation of AE signal. 100 kHz to 2 MHz range acoustic emission (AE) sensors were used to capture the signals due to crater wear. A vibration probe and an analyzer were used to measure and store the vibration during the metal cutting operation.
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CHAPTER 3
EXPERIMENTAL SET-UP AND PROCEDURE
3.1 GENERAL
Tool wear monitoring continuous to be a major area of concern in
machining. In order to produce quality products at reasonable cost tool
condition monitoring becomes an important study for all the researchers. To
monitor the tool wear during machining process an experimental study has
been carried out using acoustic emission technique (AET). Further these
experimental results are used to train Artificial Neural Network (ANN) and
Adaptive Neuro Fuzzy Inference system (ANFIS). The details of the experimental
setup, procedure, AET, ANN and ANFIS are discussed in this chapter.
3.2 EXPERIMENTAL SET-UP
Figure 3.1 shows the schematic of the experimental setup
developed in this research work. A Banka make, 5.0 HP, all – geared centre
lathe was used for machining. C45 steel of 270 BHN was used as the work
PCLNR – 16 16 K12 Tool holder were used. The tool was coated with one
layer of TiC and TiN, and thirteen layers of AlON using chemical vapour
deposition (CVD) process for better stress propagation of AE signal. 100 kHz
to 2 MHz range acoustic emission (AE) sensors were used to capture the
signals due to crater wear. A vibration probe and an analyzer were used to
measure and store the vibration during the metal cutting operation.
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Figure 3.2 shows the pictorial view of the experimental setup.
Pre – Amplifiers, power supply unit and digital oscilloscope were used to
amplify the raw signal from the acoustic emission sensors. The signals were
stored in the computer for further analysis. Lathe tool dynamometer, force
probe were used to measure the cutting forces. An ammeter was used to
measure the electrical current consumed by the motor fitted in the
experimental setup.
Figure 3.1 Schematic of the single point cutting tool wear monitoring using acoustic emission techniques 1. Work material, 2. Tool holder, 3. Tool insert, 4. Flank wear sensor, 5. Crater wear sensor, 6. Vibration probe, 7. Ammeter, 8. Pre- Amplifier, 9. Filter unit, 10. Digital oscilloscope, 11. Computer, 12. Vibration Analyzer, 13. Force probe, 14. Headstock, 15. Tool dynamometer
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Figure 3.2 Pictorial view of the experimental setup
3.2.1 Lathe Details
The specification of the all geared centre lathe used in this research
work is given in Table 3.1.
Table 3.1 Specification of centre lathe
Sl. No. Description Specification 1 Make BANKA 2 Power 5 HP, 3 Phase 3 Length of bed 1370 mm 4 Width of bed 240 mm 5 Height of centre 175 mm 6 Admit between centre 700 mm 7 Hole through spindle 40 mm 8 Swing over bed 350 mm 9 Speed of motor 1440 rpm
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3.2.2 Work Material
A harder and frequently used work material was selected to make
the research work as application oriented. The harder material was selected to
have the faster tool wear rate which would reduce the number of observations
required. Keeping these points in mind C45 steel of 270 BHN was chosen as
the work material. Also, the important properties of work material are given
in Table 3.2.
Table 3.2 Properties of work material
1. Chemical properties (Compositions - % of wt.) Carbon (C) %
C N M G 12 04 08 051 2 3 4 5 6 7 81 Shape symbol C 80 Diamond 2 Relief angle symbol N 0 Relief angle
3 Tolerance symbol M 0.08 to 0.18 – Tolerance difference is depends on insertssize.
4 Hole/chip breaker symbol G With hole (two sides) 5 Edge length symbol (ISO) 12 12.7 mm 6 Thickness symbol 04 4.76 mm 7 Corner radius symbol 08 0.8 mm 8 Manufacturer option 05 Hand symbol, chip broker symbol etc.
Coating details
i) Material Three layers of Titanium Carbide (TiC), Titanium Nitrate (TiN) and Aluminum Oxynitride (AlON)
ii) No. of layers Tic and TiN, each single layer and AlON thirteen layers iii) Coating process Chemical Vapour Deposition (CVD) process iv) Coating thickness 8 m
Pictorial view of the tool holder used for machining is given in
Figure 3.4.
Figure 3.4 Pictorial view of the tool holder with tool used
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3.2.4 Selection of AE Sensor and Pre - Amplifier
The acoustic emission (AE) sensor and pre – amplifier with filters
100 kHz to 2 MHz range is selected for the experimental work. The sensor
and preamplifiers are shown in Figure 3.5 and its specification is given in
Table 3.4.
Figure 3.5 Photographs of AE sensor and Pre-amplifier (100 kHz to 2 MHz)
Table 3.4 Specification of the AE sensor - 100 kHz to 2 MHz range and Pre-amplifier
Sl. No. Description Specification AE Sensor - 100 kHz to 2 MHz range1. Model FAC 500 2. Make Physical Acoustic Corporation 3. Sl.No. 1425874. Sensor Element Piezo – electric crystal 5. Operating Frequency Range 100 kHz – 2 MHz Pre Amplifier6. Make Physical Acoustic Corporation 7. Model 160 B; Gain :40 dB - 60 dB 8. Operating Voltage +15 V 9. Filter 125 kHz - High Pass
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Mechanically induced noises have very little energy and the peak in
the range of 20 kHz to 50 kHz. Electrical noise pick up is higher with
operating frequency. To a great extent this type of noise can be covered by
filtering out acoustic signal below 100 kHz and above 2 MHz and it will
eliminate the mechanically and electrically induced noises. Furthermore,
second attenuation in most of the engineering materials is low in this region
of 100 kHz to 2 MHz. Therefore, sensors can be placed at some distance away
from the source without the loss of signal strength. Further, the AE signal
frequency due to tool wear lie between 100 kHz and 2 MHz with significant
effect above 200 kHz. Thus, the AE sensors and pre – amplifiers with filters
to monitor crater wear are selected as the AE Sensor of 100 kHz to 2 MHz
range.
3.2.5 Filters
Filter is used to control the unwanted signals from the pre -
amplifier and the filtered signal is passed through the digital oscilloscope. The
pictorial view of the filter is shown in Figure 3.6 and the specification is
shown in Table 3.5.
Figure 3.6 Pictorial view of the Filter used in this work
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Table 3.5 Filter specification
Sl. No. Description Specification
1. Make KISTLER Corporation
2. Model 1801 – 100 H
3. Operating Voltage 15 V
4. Filter width pass 100 kHz High Band
3.2.6 Couplant
In this work Epoxy resin was used as the couplant because of its
better adherence to the sensor shoe and the surface of the tool holder and also
because of its easier availability. The use of couplants in between the sensor
and the component surface is essential for efficient detection of acoustic
emission.
3.2.7 Digital Storage Oscilloscope
The signal generated due to tool wear were captured and stored in
the digital storage oscilloscope model 1450. In this model, up to 20
waveforms can be stored. This features two identical input channels with a
maximum sensitivity of 2 m V/ div. This 1450 provides a combination of
digital storage and real time facilities and caters to measurements from DC to
20 MHz with a flicker free display. The digital method of storage provides
many advantages, notably, the facilities for storing a waveform indefinitely
and for pre – trigger viewing. The time base ranges from 0.5 µs/div to 0.2
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sec/div in NORMAL mode with additional ranges down to 50 s/div in
STORE mode. An AX10 facility expands the upper limit to 50 ns/div.
Cursor, vertical datum and horizontal datum are available on either
trace for convenience in making measurements on the traces. This also has
both RS423 serial and IEEE parallel interfaces which enables the instrument
to send stored data to an external controller (e.g. computer) and if required
receive new data for display. The Pictorial view of the digital storage
oscilloscope is shown in Figure 3.7. Also, the specification of this oscilloscope is
presented in the Table 3.6. The details of signal storing procedure “Auto arm”
and signal transfer communication software “Auto DASP” are discussed
below.
Figure 3.7 Pictorial view of the digital storage oscilloscope
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Table 3.6 Specification of the digital storage oscilloscope
Sl.No.
Description Specification
1. Make L&T OS 1450, 20 MHz dual trace and Digital facilities
2. Storage size 1024 8 bits per channel 3. Vertical resolution 1 in 256 approximately 28.5 steps/div. 4. Horizontal resolution 1 in 1024 approximately 100 samples/div. 5. Sample rate 2 MHz (0.5 s) reducing in proportion with time base6. Waveform storage Up to 20 waveforms can be stored
7. Auto arm and save Up to 20 wave forms can be successively captured and saved in backup memory.
Using this software the AE signals stored in the oscilloscope due to
wear are transferred to a computer through RS423 serial interface for analysis
at later stage. The pictorial view of the AE signal stored in the oscilloscope
and transferred to computer is shown in Figure 3.8.
Figure 3.8 Pictorial view of AE signal stored in oscilloscope and transferred into computer
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3.2.8 Profile Projector
The profile projector was used to measure the wear land of flank
wear and the propagation of crater wear extent along the rake surface. The
specification of the profile projector is given in the Table 3.7.
Table 3.7 Specification of the profile projector
Sl.No.
Description Specification
1. Work stage size 200 x 160 mm
2. Measuring traverse Longitudinal – 50 mm and Transverse – 40 mm
3. Reading accuracy 0.001 mm 4. Diameter of object Glass plate 105 mm 5. Magnification of projection lenses 10x, 25x, 50x and 100x
3.2.9 Surface Roughness Measuring Instrument
Surface roughness measuring instrument was used to measure the
maximum crater depth. The specification of the Surfcorder is shown in Table
3.8.
Table 3.8 Specification of the surfcorder
Sl.No.
Description Specification
1. Model Surfcorder model SE – 40 G, Kosaka Laboratory, Japan
2. Measuring Parameters All surface roughness parameters