Accepted Manuscript

Regular article

Condition monitoring of turning process using infrared thermography techni-

que- An experimental approach

Balla Srinivasa Prasad, K. Aruna Prabha, PVS Ganesh Kumar

PII: S1350-4495(16)30584-9
DOI: http://dx.doi.org/10.1016/j.infrared.2016.12.023
Reference: INFPHY 2204

To appear in: Infrared Physics & Technology

Received Date: 25 October 2016

Revised Date: 25 December 2016
Accepted Date: 29 December 2016

Please cite this article as: B. Srinivasa Prasad, K. Aruna Prabha, P. Ganesh Kumar, Condition monitoring of turning
process using infrared thermography technique- An experimental approach, Infrared Physics & Technology (2016),
doi: http://dx.doi.org/10.1016/j.infrared.2016.12.023

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 CONDITION MONITORING OF TURNING PROCESS USING INFRARED
THERMOGRAPHY TECHNIQUE- AN EXPERIMENTAL APPROACH
Balla Srinivasa Prasad*1 K.Aruna Prabha2 PVS Ganesh Kumar3
1*
Associate Professor, Mechanical Engg, GITAM University, Visakhapatnam, India
2
Ph.D. scholar, Mechanical Engg, GITAM University, Visakhapatnam, India
3
Scientist-G, Technology Director, Naval Science & Technology Laboratory, DRDO,
Visakhapatnam, India

ABSTRACT
In metal cutting machining, major factors that affect the cutting tool life are machine tool
vibrations, tool tip/chip temperature and surface roughness along with machining parameters like
cutting speed, feed rate, depth of cut, tool geometry, etc., so it becomes important for the
manufacturing industry to find the suitable levels of process parameters for obtaining
maintaining tool life. Heat generation in cutting was always a main topic to be studied in
machining. Recent advancement in signal processing and information technology has resulted in
the use of multiple sensors for development of the effective monitoring of tool condition
monitoring systems with improved accuracy. From a process improvement point of view, it is
definitely more advantageous to proactively monitor quality directly in the process instead of the
product, so that the consequences of a defective part can be minimized or even eliminated.
In the present work, a real time process monitoring method is explored using multiple
sensors. It focuses on the development of a test bed for monitoring the tool condition in turning
of AISI 316L steel by using both coated and uncoated carbide inserts. Proposed tool condition
monitoring (TCM) is evaluated in the high speed turning using multiple sensors such as Laser
Doppler vibrometer and infrared thermography technique. The results indicate the feasibility of
using the dominant frequency of the vibration signals for the monitoring of high speed turning
operations along with temperatures gradient. A possible correlation is identified in both regular
and irregular cutting tool wear. While cutting speed and feed rate proved to be influential
parameter on the depicted temperatures and depth of cut to be less influential. Generally, it is
observed that lower heat and temperatures are generated when coated inserts are employed. It is
found that cutting temperatures are gradually increased as edge wear and deformation developed.

Keywords: Condition monitoring, multi sensor, tool wear, vibrations, infrared thermography.

Funding agency: This work part of a Department of Science and Technology, Ministry of
Science and Technology, India funded project work titled 'Experimental Investigation of
Thermal Effects and Heat Distribution for Online Condition Monitoring of a CNC Machining
Process Using Infrared Thermography Technique and Finite Element Simulation ' through
funding order D.O: SERB-DST, New Delhi (SB/EMEQ-265/2014).

1. Introduction
The development of tool wear monitoring systems which operate in real time and make
use of direct or indirect methods, represent the typical in today's automated manufacturing.
Intensive research in the area of real time cutting tool wear monitoring systems based on infrared
thermography has begun more recently. The focal point of research was placed on the
application of multi-sensor systems and the development of computational based tool wear
classifiers so as to operate with a large number of features.
1
 Determination of the heat partition into the cutting tool and the chip during cutting) and
temperature distribution along the rake face of the cutting tool is of particular importance
because of its controlling influence on tool life, as well as, the quality of the machined part. The
temperature knowledge is essential to understand and model the phenomena involved in metal
cutting. Conventional experimental methods such as thermocouples only provide global
information which is incompatible with the high stress and temperature gradients met in the chip
forming zone [1]. During machining vibrations caused by sudden clash of a cutting tool against a
workpiece as an external excitation will affect the quality of the machining. Furthermore,
machine tools are heated because most of the supplied energy is transformed to heat and
becomes the heat source of the machine tool or an internal heat source. In addition, the spindle is
one of the largest internal heat sources. The heat distortion of the spindle (as a heat source) has
the most serious effect on the total heat distortion of the machine tool, and the heat distortion of
machine tools is the largest cause of the degradation of cutting precision [2].
Artozoul et al. [3] identified the need of temperature field measurement for deep
understanding of the thermal aspects and heat generation during cutting. This work focused on
infrared thermography applied to orthogonal cutting with an original experimental setup.
Arrazola et al. [4] expressed the importance of temperature measurement in metal cutting at the
chip and work contact. An experimental Investigation is presented to establish a temperature
dependence of tool wear and surface integrity. Infrared thermography is employed to determine
the tool side faces temperature in orthogonal cutting. John Philip et al. [5] presents the review on
the gaining popularity of Infrared thermography (IRT) as a matured and widely accepted
condition monitoring tool where the temperature is measured in real time in a non-contact
manner. Authors presented the steady growth in the use of IRT as a condition monitoring
technique in civil structures, electrical installations, machineries and equipment, material
deformation under various loading conditions, corrosion damages and welding processes.
Cho et al. [6] presented the effectiveness of using multiple sensors for the effective
monitoring of tool conditions, which is the most crucial feedback information to the process
controller. Use of multiple sensors in the classification of tool conditions, design of tool
condition monitoring system is well demonstrated. Multiple sensors tested in this paper include
force, vibration, acoustic emission, and spindle power sensor for the time and frequency domain
data. Oraby and Alajmi [7] studied the temperatures gradient, along with SEM micrographs, are
analyzed for possible correlation with both regular and irregular cutting edge deformation. It is
found that cutting temperatures are gradually increased as edge wear and deformation developed.
Kodacsy et al. [8] investigated the change of the temperature regarding the tool wear.
Roy and Ghosh [9] attempted different methods to measure the near tool-tip temperature during
turning of AISI 4140 steel with multi-layered coated insert under dry, flood cooled and minimum
quantity lubrication cooled condition. It was further attempted to identify the best technique for
assessing near tool-tip temperature. Infrared thermography has shown the closest result to that
obtained through a finite element analysis (DEFORM 3DTM) simulation. Czán et al. [10]
demonstrated a method such as infrared radiation thermography is used to measure the
temperature distribution of the tool, workpiece, and chip during metal cutting. Nickel based
super alloys are used as part of hard machining.
Abukhshim et al. [11] proposed a method for identification of maximum temperature and
temperature distribution along the rake face of the cutting tool. Different methods consisting of
experimental, analytical and numerical are adopted for results analysis. New temperature
measurement results obtained by a thermal imaging camera in high speed cutting of high strength

2
alloys are presented. Prasad et al. [12] an experimental investigation is presented of a tool
condition monitoring system, which consists of a fast Fourier transform preprocessor for
generating features from an online acousto-optic emission (AOE) signals to develop a database
for appropriate decisions. Prasad et al. [13] predicted the effects of displacements due to
vibration during face milling and to examine the correlation of surface roughness along with
progression of tool wear at different machining combinations so as to develop a base for online
tool condition monitoring system.
Real time tool condition monitoring continues to gain interest within the manufacturing
domain as new and faster sensors are being developed. Unfortunately, most tool condition
monitoring systems are still based on collecting data from the end product. From a process
improvement point of view, it is definitely more advantageous to proactively monitor tool
condition directly in the process instead of the product, so that the consequences of a defective
part can be minimized or even eliminated. In this research paper, novel method is proposed for
real time process monitoring using the combination of multiple sensors signals including,
temperature, vibrations, and tool wear measurements.
This method uses the cutting temperature and vibration signal features to detect out of
control conditions in a turning operation. Present work also focuses on the development of a test
setup for monitoring the tool condition in a turning. This kind of multiple sensor monitoring
system is employed to sense the units for tool state assessment during turning of AISI 316L steel
specimens. Feature extraction was realized by processing the detected sensor signals in order to
reduce the high dimensionality of the acquired data. The extracted features were fused to realize
a effectiveness of proposed methodology in decision making on tool wear condition. In order to
obtain accurate data about the causes of such vibrations and heat, this study measures the
vibrations and thermal changes in orthogonal cutting using a laser Doppler vibrometer and an
infrared thermography method. The aim of this work is to generate experimental database for the
development of a new, simple to use and reliable automatic method for detection and monitoring
wear on the cutting tool.
2. EXPERIMENT DESIGN FOR PRESENT WORK
Real-time condition monitoring continues to gain interest within the manufacturing domain as
new and faster sensors are being developed. But the design of tool condition monitoring system
for reduced complexity and increased robustness has been rarely studied. Therefore, present
work concentrates on design of effective multi sensor-based TCM while machining AISI 316L
steel using both coated and uncoated inserts. For this purpose, an experimental plan is designed
and it is presented in figure 1. This method takes responses from two sensors for judging the
condition of the cutting tool.

Figure 1 Proposed experiment design

This proposed tool condition monitoring system is designed to evaluate the high speed turning
operation using multiple sensors such as Laser Doppler vibrometer and infrared thermography
technique. Vibration signals were acquired by using a Laser Doppler Vibrometer (LDV) and
analyzed in time domain and frequency domain by using Fast Fourier transformation (FFT)
techniques. An FLIR infrared thermal camera is used to record the cutting temperatures
simultaneously as cutting speed and feed rate varied. Multi sensor fusion (MSF) strategy
integrates sensor data with engineering knowledge to produce quick, reliable results using
proven tool wear profile monitoring techniques. Experiments were carried out on SCHAUBLIN

3
150 High-precision lathe, Spindle speeds varies between 220-3000 rpm and main motor capacity
is 4.0/3000 kW-rpm. Maximum size of the tools this machine can be operated at is 20x20 mm.
AISI 316L steel specimens of size (Ø 5mm and length 150 mm) are used as work piece
materials. Both cotaed and un coated CNMG 150608 type carbide inserts uses as PCLNR
2020K12 as tool holder in the experiment. FLIR E60 Thermal Camera is employed to capture the
thermal images and Ometron VH300+ Laser doppler vibrometer is used to acquire the real time
vibration data during machining.
The main purpose of the study was to develop a tool condition monitoring system that
streamlines the machining process by reducing the number of process interruptions created by
tool wear. This system utilizes the findings of both infrared thermography and laser Doppler
vibrometer signals in a CNC machining operation. To isolate the significant components of the
signals collected by the multi-sensors, this study utilizes the results of thermal analysis and FFT
analysis as processing tools. As part of present investigation, an experimental test setup is
developed consisting of multiple sensors. The test setup presented in figure 2 and this setup
collects information in the form of tool tip temperature, ambient temperature and vibrations from
two different sensors.

Figure 2 Experimental test setup in Central Machine shop, NSTL, Visakhapatnam

2.1 Experimental details

• Design of the experiments
The main objective of this research is to develop anaccurate data set for the tool–chip contact
conditionsrelevant to a common industrial machining process athigh cutting speeds. Serial
experiments were carried outto clarify the effect of cutting speed on tool tip temeprature and
contact conditions. All the experimental tests wereconducted without a coolant and repeated for
differentcutting times in order to establish statistically meaningfulbehaviour. An algorithm is
developed to indiacate the different stages of the proposed investigation and this is presenrted in
figure 3.

Figure 3 Proposed methodology in the present study

3. Tool Rejection criterion adopted for in the present study
In the present study, tool rejection criteria have been assessed by using both ISO 10816 and ISO
3685. With considerations of ISO 3685 standard, three restrictions of the tool are well-thought-
out: sharp tool (tool flank wear VB = 0mm), semi-dull tool (tool flank wear VB < 0.3 mm), and
dull tool (tool flank wear VB > 0.3mm) in turning process. Optical projector machine is used to
evaluate tool flank wear. As per ISO 10816 -3 standards for vibration severity, RMS velocity of
the rotating object in 4.5 mm/sec along with acceleration and displacement is used for assessing
the condition of the tool based vibration level. ISO-18434-2008 standard is adopted for accessing
the condition of the cutting tool based infrared thermography findings.

For 316 L steel, expression for theoretical cutting temperature
 16 :

 =  ×   ×   ×   (1)
General expression for experimental cutting temperature by considering the maximum strength
and thermal conductivity [16]:

4

_ =  .   .   .   .   .   (2)

Where,  − depth of cut in mm,  − feed rate in mm/rev,  − thermal conductivity in W/ m ,

 − cutting speed in m/min,  −  SU- maximum strength in MPa,
 − theoretical cutting
temperature in ,
_ – experimental cutting temperature in , ! − is a constant and
"1, $1, %1, 1, &1 experimental coefficients.

' = ! . (! . ) ! . % ! .  ! . *! +, -- (3)

where v - is cutting speed (m/min), H- Hardness(BHN), L is the length of the cut (mm) and
"2, $2, %2, 2, &2 are exponents [12].

Table 1 Test conditions for feasibility study

4. Multi sensor fusion

Sensor data fusion plays an important role in TCM systems, as the sensors can remain
connected with the machining environment in which they are inserted. The application of sensors
with advanced and innovative technologies alone is not sufficient without the utilization of
enhanced techniques of signal processing such as data fusion methods and algorithms. They are
used to consolidate the data collected from several sensors, increasing the reliability of the
algorithms for the identification of the different states of the turning. As part of data acquisition
by these sensors, consideration is given to providing data with information in different formats.
Any necessary pre-processing would occur at the application level where the intelligent and
decision control strategies are embedded and have the capacity to generate outputs for the
functions of advanced algorithms. It is very important to adopt a functional model for sensor data
fusion for TCM system. Thus, according to this model the data processing would be divided
according to the following levels of application: signal, object, situation, and application.
Cutting tests were performed in dry condition for many reasons: dry machining development
is requested by manufacturing industries, coated carbide tools are designed for such cutting
operations, and coolant prevents proper IR temperature measurement. Figure 4a gives the
engineering data management console where vibration signal analysis is done.
• Vibration signal analysis

Figure 4a Analysis of vibration signal data

Dry machining currently induces higher cutting temperatures and lower tool life. Experiments
were carried out to observe the effects of cutting conditions, more precisely to study the
respective influence of cutting speed Vc, feed f, and depth of cut. Experiments are led using one
factor-at-a-time method. Three values for feed and depth of cut were f and d, chosen according to
tool maker’s recommendations. For the cutting speed Vc, three values were selected; with all
these values, the tool life was acceptable. Nine different cutting tests were performed within
measuring ranges of the IR camera. For the first series, only the value of the cutting speed has
varied; for the second series, it was the feed rate that has been modified; and for the third, the
depth of cut; as shown in Table 1. The repeatability of the cutting process was verified with the

5
repeatability test which lies at the three series intersection, it was carried out 10 times.
The actual implantation of the real-time monitoring system typically starts with designing
a proof-of-concept experiment. Vibration based tool wear identification is primarily subject to
the interpretation of the captured signals. In this work, a time-series analysis, applied to the wave
signals for detecting amplitude of vibration. Amplitude of vibration is expressed in terms of
percentage (%) on Y-axis as shown in figure 4b during turning. All the time domain signals in
the present work are filtered using a 0-500Hz band pass filter, and signal processing involves
signal blocks of 3200 data points collected over a sampling interval 500 milliseconds. In the
present work, vibration raw signals are gathered using an LDV and the vibration amplitude is
plotted against time domain. This form of representation is called waveform graph, and it is
shown in figure 4b which consists of time domain data. Wave graphs give the percentage of
vibration amplitude only for a particular time domain data. Hence, it is very difficult and often
impossible to quantify the vibration levels with the help of a wave graph.

Figure 4b Time domain signal Figure 4c RMS Velocity (after FFT)

Moreover, direct time-series analysis is usually incapable of isolating defect-scattered

information appropriately from noise in different frequency bands. Therefore, time domain
signal must be converted into frequency domain as spectrum graphs by using a fast Fourier
transform (FFT). Fast Fourier transform is utilized to determine the vibration parameter, i.e., rms
velocity (mm/sec) in the frequency domain for analysis of the vibration signal. Figure 4c gives
the spectrum graph for the corresponding time domain based wave graph corresponding to
turning operation. The spectrum graph presented in figure 4c provides more information about
machining process than the waveform graph. Figure 4c presents the response of dynamic signal
in the frequency domain by applying 2D-FFT to direct time signal in time domain. The rms
velocity is being plotted for the frequency. Throughout the present work, vibration parameter
considered for the experimental analysis is rms velocity and evaluation is made according to
vibration severity level mentioned in ISO 10816 standard.
• Analysis of thermal images
In figure 5 FLIR software console is presented and this is used for analysis of thermal images.
This software is used to process the thermal images. The cutting process is a highly dynamic
operation, high integration times give a blurred image; in the opposite, small integration times
provide images with more accurate geometrical description. With this equipment, the full screen
frame rate was up to 60 Hz. The focal distance was very short (i.e. 70 mm) thereby the camera
was placed very close to the observed cutting zone, as shown in figure 5.

Figure 5 Post Processing of Thermal images using FLIR Tools software

The main difficulty was then to define the different integration time values in regards to the
temperature and to geometrical parameters to be measured such as shear angle or tool / chip
contact length. The IR camera used in the experiments was a FLIR E60 equipped with a
temperature of -20°C to 650°C having resolution of 320 × 240 pixels.
5. Results and discussions
Figure 6 presents examples of images obtained at different integration times while
machining with coated CNMA insert. Figure 7 shows the thermal images when machining with
uncoated CNMA insert. Figure 6(a) & 7(a) gives the best estimation of the initial contact of tool

6
tip and work piece when the tool condition is sharp. Figure 6(b)& 7(b) gives the tool-chip
contact length and the higher temperature values with progressive tool wear. Figure 6(c) & 7(c)
summarizes the experimental results of worn tool based on IR techniques.

Figure 6(a) Figure 6(b)

Figure 6(c)

As it was noticed by Sadik and Lindström [14], contact length increases if the feed increases; it
seems independent from the depth of cut. The feed is thus the cutting parameter with the greatest
effect on contact length; this effect appears to be almost linear. From the results Table 3, it has
been observed that the value of machining time depends on the cutting conditions [15], i.e.
values for Vc, f and d. Once more cutting speed and feed are predominant, depth of the cut seems
to less influent. From the results presented in Table 2, an increase in temperature is clearly found
according to increase in cutting speed and feed rate. This trend is similar in both coated and
uncoated turning inserts and this trend is more predominant in case of uncoated insert. Cutting
tests performed at lower cutting speed should be long enough to reach the steady state condition.

Figure 7(a) Figure 7(b)

Figure 7(c)

This study measures the thermal changes and vibrations during the turning of 316L steel using an
infrared thermography camera and a Laser Doppler vibrometer. The measurement data that were
obtained from an infrared thermography camera showed that the heat distortion and the specimen
temperature were also influenced the rotational speed of the spindle.
From the results presented in figure 6 and figure 7, it is found that the tool-chip
temperature is found to be increasing along with the rotational speed (rpm) of the spindle. From
the infrared thermal images presented in figure 6 and figures 7 variations in the heat distortion
pattern is clearly evident.
As per the guidelines mentioned [17-18] about ISO-18434-2008, the temperature rise
above the ambient temperature from the thermal images is used as a parameter judging the
condition of the tool. As long as this difference if temperature value in less than 200C machining
will be stable. But machining can be continued if difference in temperature is less than 800C. If
this difference in temperature is beyond 800C then the insert is not allowed for any further
machining.
Variations in vibration levels during the turning are presented in figure 8 and figure 9.
Figure 8 gives the vibration behaviour of coated CNMG insert and figure 9 shows the vibration
behaviour of uncoated CNMG insert while machining of AISI 316L steel specimens throughout
the investigation. Vibration severity levels mentioned in ISO 10816-3 standards are used as the
basis for the judging the condition of the cutting inserts. It is clear that the rotational speed is
influencing the condition of the cutting tool and the amount of vibration while turning.
According ISO 10816-3 standard, any value of vibration parameter i.e., RMS velocity beyond
4.5 mm/sec is not acceptable. At same time, flank wear (VB) values presented in Table 2 are
found to be above 0.3 mm. As per ISO 3685 standard, turning insert has reached its optimum tool
life.

7
Figure 8(a) gives the effect depth of cut, figure 8(b) gives the effect of feed rate and figure 8(c)
gives the effect of rotational speed on vibration parameters (acceleration, velocity and
displacement) by keeping other two parameters constant.
Vibration behavior while SS 316L is machined with Coated CNMG insert

Figure 8(a) Figure 8(b) Figure 8(c)

Vibration results in figure 9(a) gives the effect depth of cut, figure 9(b) gives the effect of feed
rate and figure 9(c) gives the effect of rotational speed on vibration parameters (acceleration,
velocity and displacement) by keeping other two parameters constant in the case uncoated insert.
Results used to distinguish the performance of the coated CNMG insert over the uncoated insert.

Vibration behavior while SS 316L is machined with Uncoated CNMG insert

Figure 9(a) Figure 9(b) Figure 9(c)

During the experimentation, temperature on tool rake face is acquired through thermal images by
using FLIR E60 camera with a constant measuring distance as 0.5m. Figure 9 shows the
variation of temperature during turning process. In all test conditions, coated CNMG insert
showed relatively lesser amount of rise in the temperatures.

Tool Temperature variation with respect to Coated CNMG insert and Uncoated CNMG insert

Figure 10(a) Figure 10(b) Figure 10(c)

Thermography results presented in figure 10(a) gives the effect depth of cut, figure 10(b) gives
the effect of feed rate and figure 10(c) gives the effect of rotational speed on tool temperature by
maintaining other two parameters as constant.

Table 2 Experimental results

5. Conclusions
According to the vibration and infrared thermography data obtained from the experiments for
various cutting conditions in Table 1, it is found that the vibration parameter rms velocity values
of coated insert and uncoated insert have been enlarged by 44.71% and 65.28%, respectively. As
the results of analysis discussed above, all vibration amplitudes are principally influenced by
cutting speed, feed rate and cutting depth. The analysis and establishment of relationship cutting
tool wear with vibration signal features and rise temperature values have been carried out. The
encouraging results of the work pave the way for the development of a real-time reliable tool
condition monitoring system. The rms velocity and temperature rise show uniform trend with the
progression of tool wear. The results indicate the feasibility of using the dominant frequency of
the AOE signal and cutting temperature for the monitoring of high speed turning operations.
Temperatures rise, along with vibration signal features (rms velocity), are analyzed for possible
correlation with regular wear in case of coated insert and irregular tool wear while turning with
uncoated insert. Generally, it is observed that lower heat and temperatures are generated when
coated inserts are employed. It is found that cutting temperatures are gradually increased as edge

8
wear and deformation developed this trend is more dominant in case uncoated carbide inserts.
The proposed technique is straight forward and able to monitor the process comprehensively
with less number of features.
Acknowledgements:
The authors would like to acknowledge Director NSTL, Naval Science & Technology
Laboratory, Defence Research & Development Organization (DRDO), Visakhapatnam, India for
his support for providing both computational and experimental facilities to carry out the work.

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 Figure 1 Proposed experiment design

Figure 2 Experimental test setup in Central Machine shop, NSTL, Visakhapatnam

11
Figure 3 Proposed methodology in the present study

12
 Figure 4a Analysis of vibration signal data

Figure 4b Time domain signal Figure 4c RMS Velocity (after FFT)

13
Figure 5 Post Processing of Thermal images using FLIR Tools software

14
15
16
 Vibration behavior while SS 316L is machined with Coated CNMG insert
At, feed rate: 0.3 mm/rev, depth of cut: 0.4 mm At constant rotational speed: 1500 Rpm, Depth of cut: 0.4 mm At constant Rotational speed: 1500 Rpm, Feed rate: 0.3 mm/rev
20
Displacement(microns)

Displacement(microns)

Displacement(microns)
25 12.1
18

12.0 16
20

11.9 14
15
12
11.8
5.5
10 10
4.4
RMS velocity(mm/sec)

RMS velocity(mm/s)

RMS velocity(mm/s)
4.2
5.0
8
4.0

4.5 3.8
6
3.6
4.0 3.4
1.7 4
Acceleration (x10 -mm/s )

Acceleration(x10 -mm/s )

Acceleration(x10 -mm/s )
2

2
1.8 4

1.6
4

4
3
1.6

1.5
2
1.4

1.4 1
1000 1500 2000 0.0 0.2 0.4 0.6 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
Rotational speed, N(Rpm) Feed rate, f (mm/rev) Depth of cut, d(mm)

Figure 8(a) Figure 8(b) Figure 8(c)

Vibration behavior while SS 316L is machined with Uncoated CNMG insert

At feed rate 0.3mm/rev and depth of cut:0.4mm At constant speed of 1500 Rpm and depth of cut 0.4mm At constant Rotational speed: 1500 Rpm, Feed rate: 0.3 mm/rev
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Displacement(microns)
Displacement(microns)
Displacement(microns)

40 40
18

16
30 30
14
20 20
12

1000 1500 2000 0.0 0.2 0.4 0.6 10

10 10
RMS velocity(mm/s)

A
RMS velocity(mm/s)
RMS velocity(mm/s)

9 9
8
8 8

7 7
6
6 6

5 5 4
1000 1500 2000 0.0 0.2 0.4 0.6
Acceleration(x10 -mm/s )
2

4.0 4.0 4
A
Acceleration(10 ,mm/s )
2

3.5 3.5
3
4

3.0 3.0
2
2.5 2.5

1
2.0 2.0
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
1000 1500 2000 0.0 0.2 0.4 0.6
Depth of cut, d(mm)
A A

Figure 9(a) Figure 9(b) Figure 9(c)

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Tool Temperature variation with respect to Coated CNMG insert and Uncoated CNMG insert
180 300 300
Coated CNMG insert
Coated CNMG insert Uncoated CNMG insert Coated CNMG insert 400
200
Uncoated CNMAG insert 220 Uncoated CNMG insert
280
280 380
160
180 260 360
Tool temperature C)

260

Tool temperature C)

Tool temperatore C

Tool temperature C
0

200

0
0
340

Tool temperatore C

Tool temperature C
160 240

0
140
240
320
220
140 180 300
220
120
200
280
120
200
180 260
160
100
100 180 240
160
220
80 80 140 140 160
0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.1 0.2 0.3 0.4 0.5 1000 1200 1400 1600 1800 2000

Depth of cut,mm Feed rate, mm/rev Rotational speed, N(Rpm)

Figure 10(a) Figure 10(b) Figure 10(c)

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Table 1 Test conditions for feasibility study
Machining parameters Series 1 Series 2 Series 3
Cutting speed, m/min 225(1000), 350 350
(N-rpm) 350(1500), (1500) (1500)
475(2000)
Feed rate(mm/rev) 0.3 0.1, 0.3, 0.5 0.3
Depth of cut(mm) 0.4 0.4 0.2, 0.4, 0.8
AISI 316L specimens 3 3 3
Turning inserts with tool Coated insert (CNMG 150608) Uncoated insert(CNMG 150608)
holder PCLNR (each insert will have 4 edges) (each insert will have 4 edges)

Table 2 Experimental results

RMS Velocity Flank wear,VB
Tool rake face temp(0C)
(mm/sec) (mm)
Coated Uncoated Coated Uncoated Coated Uncoated
SNO TC
insert insert insert insert insert insert
1 TC1 3.94 4.41 89.3 96.2 0.06 0.72
2 TC2 4.04 4.92 136.5 170.4 0.09 0.14
3 TC3 5.34 6.51 173.2 198.1 0.17 0.21
4 TC4 3.5 4.02 148.5 157.3 0.22 0.26
5 TC5 3.9 4.7 215.1 244.4 0.23 0.29
6 TC6 4.41 5.68 161.7 286.5 0.26 0.33
7 TC7 5.25 6.14 215.6 224.5 0.28 0.29
8 TC8 5.95 7.25 173.3 300.1 0.29 0.37
9 TC9 9.22 11.52 285.5 391.3 0.3 0.46

19
Highlights in the present work:

• In this work both infrared thermography and laser Doppler vibrometer are used to
acquire data during turning.
• Proposed a strategy for condition monitoring which is based on both ISO-18434-2008
and ISO 10816-3.
• Experimental data is validated in real time.

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