Estimation of Life of The Cutting Tool With The Knowledge of Actual Cutting Force Acting On It

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ESTIMATION OF LIFE OF THE CUTTING TOOL WITH THE KNOWLEDGE OF

ACTUAL CUTTING FORCE ACTING ON IT
Thesis · July 2014

DOI: 10.13140/RG.2.2.22790.78407
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Akhil Aneel Deshpande

Gogte Institute of Technology
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VISVESVARAYA TECHNOLOGICAL UNIVERSITY
Belgaum – 590 018
A Project Report on
“ESTIMATION OF LIFE OF THE CUTTING TOOL WITH THE
KNOWLEDGE OF ACTUAL CUTTING FORCE ACTING ON IT”
In partial fulfilment of requirements for the award of degree of

MASTER OF TECHNOLOGY
In
MACHINE DESIGN
Submitted by
AKHIL DESHPANDE
(USN: 2GI12MMD01)
Under The Guidance Of

Dr. SHRINIVAS L. GOMBI
Professor and Head
Dept. of Mechanical Engineering
KLS’s Gogte Institute of Technology
Udyambag, Belgaum
KARNATAK LAW SOCIETY’S

GOGTE INSTITUTE OF TECHNOLOGY
UDYAMBAG, BELGAUM – 590008
2013-2014
DECLARATION
I hereby declare that the project work entitled “ESTIMATION OF LIFE OF THE
CUTTING TOOL WITH THE KNOWLEDGE OF ACTUAL CUTTING FORCES
ACTING ON IT” has been independently carried out by me under the internal guidance of
Dr. Shrinivas L. Gombi, Department of Mechanical Engineering, KLS’s Gogte Institute of
Technology, Belgaum, in partial fulfilment of the requirement for the award of degree of
Master of Technology in Design Engineering of Visvesvaraya Technological University,
Belgaum.
I further declare that I have not submitted this report either in part or in full to any
other university for the award of any degree.
AKHIL A. DESHPANDE
USN: 2GI12MMD01
ACKNOWLEDGEMENT
“Gratitude is the memory of heart”
-Goes the saying and expressing hearty thanks is always the pleasant thing.
First of all I thank the God Almighty for his grace and mercy that enabled me in the
finalization of this project.
I express my sincere gratitude to Principal, Dr. A. S. Deshpande for providing the

laboratory and necessary facilities.
I am greatly obliged to Dr. Shrinivas L. Gombi, HOD of Mechanical Engineering for

helping me to choose this topic and also for being my project guide and constantly
encouraging and supporting me throughout the project phase, without which this project
would not have been a successful one.
I would like to thank Dr. G. R. Udupi and Prof. Santosh Saraf, Faculty, Department of
Electronics & Communication Engineering, for helping me to understand the NI
LabVIEW software and logic to build the circuits for conducting of my project.
I am immensely indebted to all the teaching and non-teaching staff of Department of

Mechanical Engineering for their constructive criticisms, guidance, advices and for
providing me all the help I needed for successful execution of my project work.
I on this occasion, remember the valuable suggestions and prayers offered by my family
members and friends which were inevitable for successful completion of my project.
AKHIL A. DESHPANDE
(2GI12MMD01)
i
ABSTRACT
In the manufacturing systems such as Flexible Manufacturing Systems (FMS), one of
the most important issues is to estimate cutting tool life under a given cutting conditions as
accurately as possible. The classical formula for estimating the cutting force on the tool gives
an average value of the cutting force. But due to the impact effect that comes on to the
cutting tool at very first instance of cutting when tool impacts the work-piece, which is nearly
1.1 to 1.5 times of the average cutting force, the actual life of the tool considerably reduces
leading to premature failing of the tool. Many a times force dynamometers are not available
for machines like shaper. Hence indirect estimation of the actual cutting force becomes
essential. In this project we deal with the estimation of the cutting tool life considering the
impact effect on it from measurement of responses during machining. The impact force
cannot be directly measured while response signals are easily obtained using transducers such
as accelerometers or strain gauges. In many structural evaluation tests, the dynamic response
is not sufficient information; one may really need a description of the input force. A most
preferred approach to address this problem is to determine the Frequency Response Function
(FRF) matrix, measure the structural responses, and calculate the dynamic forces based on
Least Squares scheme. The forces obtained by this approach are prone to errors. These arise
due to a combination of errors in the measurements and high condition numbers in the matrix
of transfer functions to be inverted. Ill conditioning of the FRF matrix causes measurement
errors to be magnified significantly. The acceleration response is used as input for force
prediction. The impact force history prediction algorithm is developed in frequency domain
to determine the impact force amplitude. The force estimation problem is thereby constructed
and is then solved for determining the amplitude of the impact force. By conducting iterative
experiments and using this force the life of the cutting tool can be estimated.
ii
CONTENTS
Acknowledgement i
Abstract ii
Contents iii
List of Figures vi
List of Tables ix
Chapter 1: Introduction 01
Chapter 2: Literature Review 03
2.1: Forward and Inverse Problems 03
2.2: Force Identification as an Inverse Problem 03
2.3: Analysis of Impact Force Identification 04
2.4: Tool Life and Condition Monitoring 05
2.5: Summary of Literature Review 06
Chapter 3: Forward and Inverse Problems 07
3.1: Force Identification as an Inverse Problem 08
Chapter 4: Analysis of inverse Force Identification 11
4.1: Time Domain Analysis 11
4.2: Frequency Domain Analysis 12
4.3: Frequency Response Function (FRF) 15
Chapter 5: Factors affecting Tool Life 16
5.1: Cutting Force 16
5.2: Cutting Speed 17

iii
5.3: Feed and Depth of Cut 17
5.4: Tool Geometry 17
5.5: Tool Material 17
5.6: Work material 18
5.7: Cutting Fluid 18
5.8: Tool Wear 18
5.9: Presence of Magnetic Field 19
Chapter 6: Problem Definition 20
6.1: Problem Description 20
6.2: Problem Statement 21
6.3: Objective of the Project 21
6.4: Working Method 21
6.5: Methodology Steps 22
Chapter 7: Equipments used in the Experimentation 23
7.1: Impact Hammer 23
7.2: Accelerometer 24
7.2.1: Methods of Accelerometer Mounting 25

7.2.2: Accelerometer Specifications 27
7.3: DAQ and LabVIEW Software 28
7.3.1: DAQ (Data Acquisition) 28

7.3.2: DAQ Device/ Hardware 29
7.3.3: About NI DAQ 30
7.3.4: Advantages of NI DAQ 30
7.3.5: Physical Input/ Output Signals 31
7.3.6 Introduction to LabVIEW Software 33
iv
Chapter 8: Extraction of Frequency Response Function (FRF) 35
Chapter 9: Estimation of Impact Force 39
Chapter 10: Theoretical Cutting Force Magnitude and Estimation of the Tool Life 47
Chapter 11: Results and Discussions 68
Conclusion 70
References 71
Publication 73
APPENDIX 74
v
LIST OF FIGURES
FIGURE PAGE
FIGURE NAME
NO: NO:
3.1 Schematic representation of Forward and Inverse Problems 7
4.1 Simple plate excitation/response model 12
4.2 Simple plate response 13
4.3 Simple plate frequency response function 14
4.4 Overlay of time and frequency response functions 14
4.5 Linear system with displacement response due to the input force 15
6.1 Schematic sketch of the impact force coming onto the shaper tool at
the instance of cutting 20
7.1 Impact Hammer used to excite the vibrations 23
7.2 Impact Hammer Response Curves 24
7.3 Depiction of few piezoelectric accelerometers 25
7.4 (a) A Typical screw mounts 25
7.4 (b) A Typical Adhesive Mount 26
7.4 (c) Magnetic mounting 26
7.5 Process of data acquisition 28
7.6 NI DAQ (CDAQ 9234) used for data acquisition process 29
7.7 A typical LabVIEW Circuit used for Data Acquisition of force and
acceleration 34
8.1 Experimental setup to determine the FRF of the cutting tool 35
8.2 LabVIEW circuit constructed for acquiring signals for the fixed
duration of 3 seconds 36
8.3 The output of the LabVIEW program displaying force and acceleration
data for time span of 3 seconds 36
8.4 Acceleration and Impact force data in time domain. 37
8.5 FRF curve for the above data 37
8.6 Acceleration and Impact force data in time domain. 38
8.7 FRF curve for the data obtained in figure 8.6 38
9.1 Position of the cutting tool in the tool holder of shaper machine 39
9.2 FRF curve used to predict the cutting force 40
9.3 (a) Predicted force at the depth of cut of 0.5mm for 1st Impact 41
vi
9.3 (b) Predicted force at the depth of cut of 0.5mm for 2nd Impact 41
rd
9.3 (c) Predicted force at the depth of cut of 0.5mm for 3 Impact 41
9.4 (a) Predicted force at the depth of cut of 1mm for 1st Impact 42
9.4 (b) Predicted force at the depth of cut of 1mm for 2nd Impact 42
9.4 (c) Predicted force at the depth of cut of 1mm for 3rd Impact 42
9.5 (a) Predicted force at the depth of cut of 1.5 mm for 1st Impact 43
nd
9.5 (b) Predicted force at the depth of cut of 1.5 mm for 2 Impact 43
rd
9.5 (c) Predicted force at the depth of cut of 1.5 mm for 3 Impact 43
9.6 (a) FRF Curve 1 used to predict the cutting force 44
9.6 (b) FRF Curve 2 used to predict the cutting force 44
9.6 (c) FRF Curve 3 used to predict the cutting force 44
9.7 (a) Force predicted by the algorithm using FRF data from figure 8.6 (a) 45
9.7 (b) Force predicted by the algorithm using FRF data from figure 8.6 (b) 45
9.7 (c) Force predicted by the algorithm using FRF data from figure 8.6 (c) 45
9.8 Predicted failure force at the depth of 1.8mm with multiple impacts. 46
10.1 CAD model of the tool showing cross section area of the tool at plane
0.5 mm from the tool tip. 48
10.2 Miner’s method for predicting tool life for experimentally obtained
force of 97.32 N. 50
10.3 Miner’s method for predicting tool life for theoretically obtained force
of 40.423 N. 52
1 mm from the tool tip. 54
of 73.37 N. 57
1.5 mm from the tool tip. 59
force of 117.03 N. 60
of 103.98 N. 62
vii
10.10 CAD model of the tool showing cross section area of the tool at the
plane 1.8 mm from the tool tip. 63
of 121.663 N. 67
viii
LIST OF TABLES
TABLE PAGE
TABLE NAME
NO: NO:
7.1 Detailed specification of accelerometer PCB 352C03 27
7.2 Input characteristics of NI CDAQ 9234 32
11.1 Comparison of experimentally obtained cutting force with predicted
cutting force at different depths of cut. 68
11.2 Comparison of experimentally obtained cutting force with theoretical
cutting force and tool life for each at different depths of cut. 69
ix
ESTIMATION OF LIFE OF THE CUTTING TOOL WITH THE KNOWLEDGE OF ACTUAL
CUTTING FORCE ACTING ON IT
Chapter 1
INTRODUCTION
Recent advancement of technology has made it possible to design and develop
machines and structures to carry out tasks more efficiently hitherto not possible. Because of
the competition among the industries and scarce availability of materials, it has become
essential to optimize and redesigning of the products.
For the analysis and design of structural systems and machines, the estimation of real
input loads is a very important and necessary task. By way of determining the dynamic loads,
many problems, such as the strength, fatigue and reliability of structures and machines can be
evaluated adequately. But in most of the conventional design processes, generally the
response of a structure or a machine is determined for an assumed applied force. Such
problems may be described as direct or forward problems as they involve the determination
of the unknown effects of a known cause. Finite element method is one such powerful tool,
helping in carrying out the analysis in refining the design of a product [1]. In the forward
Finite element method, during the analysis of a structure or a machine member, an estimated
load is applied and the analysis is carried out. But when the load coming on the member itself
is not exactly known, analysis on the basis of estimated load is only approximate. Also,
during the design of certain structures and machines, more emphasis is given to their
functional aspects than the strength requirements under the actual operating loads. Some
time, this may lead to over designing of the components of machines or structures causing
over utilization of material and cost. Hence, along with maintaining the functional integrity, if
the structural or machine components are designed for the actual operating loads, there is lot
of scope for optimizing the component sizes, considerable saving of scarce materials or use
of alternative materials.
Thus, the knowledge of the operating dynamic forces is an essential requirement

during the design and optimization stages of mechanical systems. However, the detailed
information about these forces is usually not available as the direct measurement of these
forces under running conditions is either very difficult or not feasible at all. This makes
alternative methods of force estimation necessary and very valuable. Cutting forces of
machine tools, supporting forces of bearings, aerodynamic forces on various machine
M.Tech. Machine Design

Department of Mechanical Engineering KLS’s GIT, Belgaum 1
components and excitation forces on rotating machines are some examples to illustrate the
need for alternative methods to identify the dynamic forces [2]. Inverse technique of force
identification using measured structural responses is one such alternative method to identify
the dynamic forces.
The Inverse Technique has many wide verities of applications some of which are load
estimation as in the case of Vehicles, structures, machines, Structural Health Monitoring
(SHM) etc.
In the present project work an attempt is being made to estimate the life of the cutting
tool of shaper using an inverse technique for the identification of the operating forces on a
structure or a machine from the measured vibration responses. With the knowledge of these
actual operating forces, the estimation of life of cutting tool of a shaper is achieved.
Accelerometer responses and impact hammer responses are used for extracting the FRFs of
the cutting tool which are then used in prediction of the actual force. The methodology is
discussed in detail in the further chapters.

Chapter 2
LITERATURE REVIEW
Literature review acts as backbone of the whole project, since the determination of
dynamic forces is very complex. To understand the background theory and about design of
machine tools, it takes long time. This chapter deals with study of forward and inverse
problems, force identification as inverse problems and methodology used to predict cutting
forces on the shaper tool and its cutting life.
2.1 Forward and Inverse Problems

Uhl, T., Mendrok K. [3] In this paper an overview of a loading force identification
technique is presented. Load identification methods are based on the solution of the inverse
identification problem. For both linear and nonlinear systems, methods based on the
minimization of assumed objective functions have been formulated. The least square error
between the simulated and measured system responses has been used as the objective
function. The dynamic programming optimization method formulated by Bellman is
commonly used for the minimization of the objective function to estimate the excitation
forces. The inverse identification problem in most practical cases is ill-posed because not all
the state variables or initial conditions are known. Ill-posed inverse identification problems
can be solved using several techniques, the most useful of which are: the generalized cross-
validation method, the dynamic programming technique and Tikhonov’s method. In this
paper the theoretical background and main limits to the application of inverse identification
methods are presented. Numerical and experimental tests on a laboratory rig were made to
verify the formulated procedures. The method has been applied to the identification of
wheel–rail contact forces during rail vehicle operation. The method can be applied for
indirect measurements of contact forces in railway equipment testing.
2.2 Force Identification as an Inverse Problem

K. K. Stevens [5] In this paper several techniques for indirect force identification, operating
either in the time domain or in the frequency domain, have been proposed. How the impacts
cause dynamic effects on the system is analysed in this paper.

G.S. Whiston [6] In this paper a technique for remote impact analysis applicable to on-line
vibration wear assessment of installed plant is presented. Beam acceleration transients
propagated from impact sites have been spectrally inverted to yield the impact site location
and the force time history. The effect of various possible types of signal contamination has
been analyzed.
2.3 Analysis of Impact force Identification

M. T. Martin and J. F. Doyle [7] Inverse problem of solving the impact force history using
experimentally measured structural responses that tends to be ill-conditioned is converted
into a well-conditioned problem using frequency domain deconvolution method. This helps
in clarifying fundamental difficulties and issues involved in this problem. In this paper force
reconstruction obtained using experimentally measured acceleration responses from four
example structures are used to illustrate the points.
Bor- Tsuen Wang, Kuan- Yuan Lin [8] In this paper the force prediction for cantilever
beam subjected to harmonic excitation is presented. Assuming the structural parameters
known, the acceleration response of the beam due to the harmonic excitation is also measured
and used as the input for the prediction model. Using the developed force prediction
algorithm harmonic force amplitude and its location is determined simultaneously. The beam
response excited by harmonic force is first derived. The optimization problem to determine
the harmonic force amplitude and location is then formulated. Theoretical simulation is
presented to demonstrate the feasibility and correctness of the developed force prediction
algorithm. Experimental verification is carried out to validate the prediction model. The
results of this experiment show that the harmonic force amplitude and its location can be
reasonably predicted.
Shrinivas L. Gombi and Dr. D. S. Ramakrishna [9] In this work effect of impact force on
the shaper tool during machining is estimated. A most preferred approach is addressed to this
problem in determining the Frequency Response Function (FRF) matrix. The structural
responses are measured and dynamic forces are calculated based on the Least Square
Scheme. In this paper acceleration response is used as input for force prediction. The impact
force history prediction algorithm is developed in both time and frequency domains to
determine the impact force amplitude. In time domain the accelerations due to impact load is
first predicted. The sum of mean square errors problem is thereby constructed and is then

solved for the amplitude of the impact force. The accelerance method is used in the frequency
domain. Results show that the method outlined for the identification of the magnitude of the
impact force, apart from being accurate and robust to the effects of measurement noise, may
be extended to solve problems for more general nature.
Brian J. Schwarz and Mark H. Richardson [10] Experimental Modal Analysis has grown
steadily in popularity since the advent of the digital FFT spectrum analyser in the early
1970s. Today impact testing has become wide spread as a fast and economical means of
finding the modes of vibration in a machine or structure. In this paper all the main topics
associated with experimental modal analysis is reviewed, including making of FRF
measurements with a FFT analyser, Modal Excitation Techniques and Modal Parameter
Estimation from a set of FRFs
2.4 Tool Life and Condition Monitoring

Wager and Barash [11]The work deals with the study of the distribution of the life of HSS
tools when machining low carbon steel and find that tool life values are approximately
normally distributed with a coefficient of variation of about 0.3. Their main conclusion is that
tool life predictions should be made on a probabilistic basis. The tool life criterion considered
in their experiments is complete failure of the cutting edge- Negative rake tests show that
although there is a tendency to bimodality and positive skewness, the tool life distribution can
be approximated by a normal curve. Positive rake tests show that while the nature of the tool
life distribution is similar to that of the previous case, the occurrence of a few values of quite
long life suggests the relevance of the log-normal distribution, which has been found to apply
in the case of repeated fatigue testing. It is observed that despite the fact that all tools were
supposedly from the same batch and cutting conditions within a series of tests were held as
constant as possible, analysis of variance showed significant differences between means of
tests on tool lives. Specifically referring to drills, information available from several drill
manufacturers states that the distribution of drill life can be taken as normal at a first
approximation.
Variations in tool life cannot be attributed to "experimental error," but rather are the
inherent physical nature of the process which, like so many other physical processes, is
stochastic. Finally, it is concluded that tool life reaches a maximum at a certain speed, and

drops off in both directions. For HSS tools, this peak is close to zero speed, but for carbides,
it is known to be at a significant value, so that on a log-log plot, tool life is represented by
two straight lines which meet at a point.
P.N. Botsaris and J.A. Tsanakas [12] In this work a summary of the monitoring methods,
signal analysis and diagnostic techniques for tool wear and failure monitoring have been
proposed, tested and reported in literature up today. The paper, lists the basic parameters that
are correlated with each type of fault. Both direct methods, such as computer vision, and
indirect methods, such as vibration, that have been used to monitor these parameters, are
presented. Moreover, the paper summarizes the signal processing techniques that have been
applied to each monitoring method, including e.g. statistical parameters and Wavelet
Transform. Following this, a number of diagnostic tools, which have been developed for
diagnosis of tool condition, are presented. The paper concludes that the area of condition
monitoring and fault diagnosis is of increasing importance, stressing the fact that only few
implementations have been achieved, as a consequence that all available techniques present
drawbacks and limitations.
2.5 Summary of Literature Review

After doing literature review on forward and inverse problems and taking force as an
inverse problem and analysis of it we can understand that
The inverse problems need to be well posed or well-conditioned and ill-conditioned

problems need to be converted into well-conditioned problems using regularization
methods
Forces coming on to cutting tools during machining are unknown and such problems
are considered as inverse problems
Using Modal analysis it is simple to analyse the unknown force. Using this unknown
force further optimization can be carried out.

Chapter 3
FORWARD AND INVERSE PROBLEMS

In the dynamics of mechanical structures two main problems can be distinguished: the
forward problem and the inverse problem [3]. These problems are shown schematically in
block diagram schemes in Figure 3.1
The forward problem deals with predicting the output or response for the known input
condition. It is represented as shown in Figure 3.1 (a).
The second type is the inverse problem which can be classified as:
a) Finding system inputs, based on given responses, boundary conditions and system
model (the inverse identification problem). It is shown in Figure 3.1 (b).
b) Finding the system model based on given inputs, responses and boundary conditions
(the classical identification problem). It is shown in Figure 3.1 (c).
Fig. 3.1 Schematic representation of Forward and Inverse Problems [3].
In many practical cases the boundary conditions are not known but the locations of
loads (inputs) are known. The task is then limited to the determination of the time history or
spectrum of operational loading forces.
The inverse problems are found in numerous fields such as geophysics, seismology,
medical diagnosis, physics, and mechanics. A majority of applications are related to the
search of hydrocarbon traps, medical topography, microwave, and ultrasonic detection of
damages since the interior region needs to be reconstructed or identified from measurements

[4]. This problem often arises because the measurements can only be taken at some readily
accessible locations or a state variable can only be measured indirectly or direct
measurements are not possible or feasible. The force identification problem, an inverse
problem, is to utilize measured structural response, such as strain, acceleration, velocity and
displacement, to estimate the spatial distribution of the force and time history of the force.
3.1 Force Identification as an Inverse Problem
Due to the dynamic effects, impacts cause extensive damage to structures and
machine components [5]. This also severely degrades the load carrying capability of the
structure and machine components. Considering the effects of impact loading on the integrity
and serviceability of the structures and machines, it is necessary to have a better
understanding of the loading profile, such as spatial distribution and loading time history. The
loading profile is also very important for optimum design of structures and machines;
however it is difficult to obtain the loading profile in an actual engineering application. The
traditional way of direct sensing requires an access to the impact locations. Therefore, it is
very difficult to measure operating load history due to the complex nature of the impact
loading or danger that arises in the actual situation. On the other hand it is routinely
convenient to measure the structural response at remote points from the impact locations. A
properly formulated inverse procedure will be useful for the reconstruction of the impact
loading profile using the structural responses obtained at a distant point from the impact
location.
The identification of impact force includes two relevant aspects, i.e. identification of
impact force history and estimation of force location. In the field of identification of impact
force history, the most straight forward technique employed by many researchers is
deconvolution based on the assumption that the response of a body subjected to impact force
is linearly dependent on the impact force. This technique can be employed both in the time
domain and the frequency domain.
Another basic scheme for deconvolution is to employ a relationship in the frequency

domain transformed from the time domain using Fast Fourier Transformation (FFT). Fourier
transforms are defined by infinite integrals, but truncation of data to a finite length is
necessary for practical computations, which introduces a discontinuity at the end of the data

and causes errors. Also, besides Fourier transform, the applications of the Laplace
transformation for identification of impact force in the frequency domain have also been
investigated.
It is well known that inverse problems are often ill posed in the mathematical sense,
that is one of these, i) existence ii) uniqueness or iii) stability of the solution is violated [6].
This is also the case in the inverse problem of identification of impact forces and it causes
many difficulties in obtaining good estimates of the impact force. Generally, for identifying
the impact force history, the values of impact force at many discrete time points in the time
domain are directly employed as unknown parameters to approximate the impact force
history. If the mode superposition method is used to setup the relationship between the
concentrated impact force and the responses, for instance, through Green’s functions, the
obtained optimization model for solving the inverse problem is usually ill-conditioned when
using the traditional least squares method. In an actual system, the identified histories have
large oscillations due to influences of measurement noises or accuracy of the numerical
model. Several mathematical techniques, classed as regularization techniques, for achieving
the relaxation of the ill posedness have been established. For such ill posed problem the
regularisation process can be incorporated. Regularisation is defined as the process of
transforming an ill posed problem into a well posed problem by using additional information
about the sought solution is called regularisation process. Few regularisation methods are as
below.
• Generalised cross validation.

• Singular Value Decomposition (SVD)
• Iterative method
• Data filtering approach
• Tikhonov regularisation method
SVD is most commonly used technique to obtain a stable solution with a physical sense.
One of the applications of inverse techniques is in the field of life estimation of

machine tools using the identified operational cutting forces. Generally it is observed that the
machine tools are designed using equations from data hand book for the average cutting
force. The tool fails at much lower age as compared to the life predicted by the tool

manufacturers. To overcome this, the tool life is to be re-estimated with the knowledge of the
actual operational cutting forces. Cutting forces at the tool-chip interface have long been
recognized as major factors that influence the tool performance. During tool machining, large
external forces are imposed in the region of the tool cutting edge, the rate of wear of the
cutting tool and the friction between work piece and tool depend strongly on these external
forces. The direct measurement of the spatial and temporal-dependent external forces by
using traditional type of sensors is impossible due to the cutting tool movement and the
presence of the chip. Due to the fact that, the direct sensing of tool-chip interface forces is
difficult, the use of the inverse techniques can be a good alternative since this technique takes
into account the displacements/accelerations measured from accessible positions of the
cutting tools.

Chapter 4
ANALYSIS OF INVERSE FORCE IDENTIFICATION
Many cases arise in practice where it is necessary to know the dynamic impact force,
but where it is not possible to instrument the impactor. One such example is the estimation of
the impact force which acts on the cutting tool of shaper when the tool comes and hits the
work-piece during the first instance of cutting, where it is difficult to place any force
measuring instrument. This impact force is 1.1 to 1.5 times the average cutting force. The
inverse problem of solving for the impact force history using experimentally measured
structural responses tends to be ill conditioned. Frequency domain deconvolution method is
used to solve the problem [7]. In this chapter we discuss in detail about the Time Domain
analysis, Frequency Domain Analysis and how Frequency Response Function (FRF) is used
in estimation of dynamic force.
4.1 Time Domain Analysis
The response of a body to an impact force can be considered to be linearly dependent

on the impact force [9]. In such cases, the response x(t) at a point on the body can be related
to the impact force f(t) by linear convolution integral as:
= ℎ − (4.1)
Where h(t) is the impulse response function (IRF) of the linear system and it is
assumed that f(t) = h(t) = x(t) = 0 for t < 0.If the IRF for the chosen point on the body is
known and if response x(t) is measured there, the impact force f(t0 can be estimated by
solving the integral equation (4.1).
A basic scheme for deconvolution is to discretize the integral equation (4.1) into
algebraic equations in the time domain as:
x = hf (4.2)
Where x and f are vectors composed of discrete values of x(t) and f(t), respectively
and h is the matrix composed of discrete values of h(t). In this project the impact force can be
identified by solving equation (4.2) for f.

4.2 Frequency Domain Analysis
Modes are used as a simple and efficient means of characterizing resonant vibration.
Resonant vibrations are caused by interaction between the inertial and elastic properties of
the materials within a structure. As per Brian J. Schwarz et al [10], modes are inherent
properties off a structure. Resonances are determined by the material properties such as mass,
stiffness, and damping properties and boundary conditions of the structure. Each mode is
defined by a natural frequency, modal damping and a mode shape.
Modal analysis as defined by Peter Avitabile [13] is a process whereby is described

as a structure in terms of its natural characteristics or its dynamic properties which are the
frequency, damping and mode shapes. Often modal analysis is explained in terms of the
modes of vibration of a simple plate.
Consider a freely supported flat plate as shown in figure 4.1
Fig. 4.1 Simple plate excitation/response model [13].
A constant force is applied to one corner of the plate. One usually thinks of a force in
a static sense which would cause some static deformation in the plate. But here the applied
force varies in a sinusoidal fashion. Consider a fixed frequency of oscillation of the constant
force. The rate of oscillation of the frequency is changed but the peak force is maintained at
the same value i.e. only the rate of oscillation of the force is changed. The response of the
plate due to the excitation is measured with an accelerometer attached to one corner of the
plate. The response is given by:
{X (ω )} = [H (ω )]{F (ω )} (4.3)
Therefore {F (ω )} = [H (ω )]−1 {X (ω )}. (4.4)

Where {X (ω)} is Response vector

[H (ω)] is FRF Matrix (m = n)
{F (ω)} is Force vector
If the FRF matric [H (ω)] is not a square matrix i.e. m ≠ n, a technique called Moore-
Penrose Pseudo-Inverse of matrices is applied [14]. It is a concept that generalizes the usual
notion of inverse of a square matrix, but that is also applicable to singular square matrices or
even to non-square matrices. This notion is particularly useful in dealing with linear least
squares problems. This method is also known as Singular value Decomposition (SVD).
{F (ω )} = [H (ω )]+ {X (ω )}. (4.5)
[H (ω )]+ = ([H (ω )]* [H (ω )]) [H (ω )]*

−1
Where (4.6)
Therefore {Fˆ (ω )}= ([H (ω )] [H (ω )])

* −1
[H (ω )]* {X (ω )} (4.7)
Now when the response is measured it is seen that that the amplitude changes as the
rate of oscillation of the input force changes as in figure 4.2. There will be increases as well
as decreases in amplitude at different points for a given period of time. This seems very odd
since a constant force is applied to the system, yet the amplitude varies depending on the rate
of oscillation of the input force. But this is exactly what happens, the response amplifies as a
force is applied with a rate of oscillation that gets closer and closer to the natural frequency
(or resonant frequency) of the system and reaches a maximum when the rate of oscillation is
at the resonant frequency of the system.
Fig. 4.2 Simple plate response [13].

This time data provides very useful information. If the time data is transformed into
the frequency domain using the Fast Fourier Transform then Frequency Response Function
(FRF) can be computed as shown in figure 4.3. It is observed that there are peaks in this
function which occur at the resonant frequencies of the system and these peaks occur at
frequencies where the time response was observed to have maximum response corresponding
to the rate of oscillation of the input excitation.
Fig. 4.3 Simple plate frequency response function [13].
When the time trace with the frequency trace is overlapped one can notice that the
frequency of oscillation at the time at which the time trace reaches its maximum value
corresponds to the frequency where peaks in the frequency response function reach a
maximum as shown in figure 4.4. Thus the time trace can be incorporated to determine the
frequency at which maximum amplitude increase occur or the frequency response function
can be incorporated to determine where these natural frequencies occur. Clearly the
frequency response function is easier to evaluate.
Fig. 4.4 Overlay of time and frequency response functions [13].

4.3 Frequency Response Function (FRF)
The frequency response function is defined as a very simply the ratio of the output
response of a structure due to an applied force [13]. The applied force and the response of the
structure due to the applied force is measured simultaneously. (The response can be measured
as displacement, velocity or acceleration.) Now the measured time data is transformed from
the time domain to the frequency domain using a Fast Fourier Transform algorithm found in
any signal processing analyzer and computer software packages.
Due to this transformation, the functions end up being complex valued numbers; the
functions contain real and imaginary components or magnitude and phase components to
describe the function.
Consider a linear system as represented in the figure 4.6
Fig. 4.5 Linear system with displacement response due to the input force.
Where F(ω) is the input force as a function of the angular frequency ω. H(ω) is the
transfer function. X(ω) is the displacement response function. Each function is a complex
function which can be represented in terms of magnitude and phase. Each function is thus a
spectral function. The relationship between input and output is represented by equation 4.3.
And the FRF H(ω) is given by
H ω = (4.6)

Chapter 5
FACTORS AFFECTING TOOL LIFE
Tool life can be defined as the time interval for which the tool works satisfactorily
between two successive grindings [15]. Thus, it can be basically conceived as functional life
of the tool. The tool is subjected to wear continuously while it is operating. Obviously, after
some time, when the tool wear is increased considerably, the tool losses its ability to cut
efficiently and must be reground. If not it will totally fail. The life can be effectively used as
the basis to evaluate the performance of the tool material, access machinability of the work
piece material and know the cutting condition.
Following are the factors affecting the tool life of the cutting tool [15, 16, 17].
1. Cutting force
2. Cutting speed
3. Feed and depth of cut
4. Tool geometry
5. Tool material
6. Work material
7. Use of cutting fluid
8. Tool Wear
9. Presence of magnetic field
5.1 Cutting Force

The performance of the cutting tool or the machinability of the work material can be
evaluated by measuring the cutting forces. An increase in cutting force increases the
likelihood of chipping of the cutting edge through mechanical shock. Gradual tool wear also
occurs due to the increasing friction between tool and workpiece.
Cutting forces are affected by experimental conditions such as cutting conditions,

workpiece material and type of the tool; for example, the faster feed rate, the higher cutting
forces are measured, fact that may cause confusion about whether the increasing of cutting
forces is due to tool wear or changes in the cutting conditions.

5.2 Cutting Speed

Speed has the greatest influence on tool life. As the cutting speed increases the
temperature also rises. The heat is more concentrated on the tool than on the work and the
hardness of the tool matrix changes so the relative increase in the hardness of the work
accelerates the abrasive action. The criterion of the wear is dependent on the cutting speed
because the predominant wear may be wear for flank or crater if cutting speed is increased.
5.3 Feed and depth of cut

The tool life is influenced by the feed rate also. With a fine feed the area of chip
passing over the tool face is greater than that of coarse feed for a given volume of material
removal, but to offset this chip will be greater hence the resultant pressure will nullify the
advantage.
5.4 Tool Geometry

The tool life is also affected by tool geometry. A tool with large rake angle becomes
weak as a large rake reduces the tool cross-section, increases the shear angle and reduces the
amount of metal to absorb the heat. This will reduce the cutting force and power and hence
the heat generated during cutting. This means reduced cutting temperature resulting in longer
tool life. But increasing the rake angle will reduce the mass of metal behind the cutting edge
resulting in poor transfer of heat. This can tend to increase the cutting temperature. Also yhe
cutting edge becomes mechanically week resulting as a guide; there is an optimum value of
rake angle of 14o which gives maximum tool life.
5.5 Tool material

The major requirements of cutting tool materials are:
Hot hardness
Impact roughness
Wear and abrasion resistance.
High hardness gives the tool good wear resistance but its toughness decreases. For thermal
shock resistance, the tool material should have high thermal conductivity and specific
heat, a low co-efficient of thermal expansion and high tensile strength.
The variation in the above tool material requirements with cutting temperature are of
considerable importance to tool life.
5.6 Work material

Physical and chemical properties of tool and work material influence the tool life by
affecting the form stability and rate of wear of tool. As the hardness of the work material
increases, the power consumption and temperature increases. This increases tool wear and
resulting in shorter tool life. Impurities in the work material increases tool wear. Micro-
structure of work material is very significant since there is great variation in hardness of
micro-constituents of an alloy. Pure metals tend to adhere to the tool surface and give high
friction and high wear rates resulting in shorter tool life.
5.7 Cutting fluid

Coolants are used to decrease tool operating temperature and improve cutting
performance. A good cutting fluid should act as a lubricant as well as removing the heat
(coolant) from the cutting zone.
Water is a good coolant, but is a poor lubricant and presents corrosion (rust) hazard. On
the other hand, oil is a good lubricant but is less effective in cooling.
In practice, emulsion combinations of oil and water or wax and water are used as cutting
fluids.
5.8 Tool Wear

The temperatures over the contact surfaces are pretty high. Each time the tool enters or exits
from the cut, it is subjected to mechanical as well as thermal shock. Under such adverse
conditions, the hard tool materials like HSS and carbides, etc. Gradually wear out and even
fracture, necessitating a tool change. The machine has to be stopped during the time the tool
is being retracted, changed and returned into the cutting position. Precious machining time is
lost in the process. Tool wear and the time between two successive tool changes (tool life)
are, therefore, subjects of great importance in the theory and practice of metal cutting.
Tool wear or tool failure may be classified as follows:
(a) Flank wear.
(b) Crater wear on tool face.
(c) Localized wear such as the rounding of the cutting edge,
(d) Chipping off of the cutting edge.

5.9 Presence of magnetic field

The magnetic field- material interaction model shows an exponential dependence of
material behaviour and mechanical property, changes on applied field strength [17]. The
changes in mechanical properties like hardness, roughness, wear resistance as discussed
above, results in alteration of tool life.

Chapter 6
PROBLEM DEFINITION
This chapter deals with description of the work and the methodology adopted for
reaching the desired objective of the work.
6.1 Problem Description
The life of the cutting tool is a serious concern in manufacturing industries. Premature
tool failure leads to increase in process lead time and reduction in productivity. As the tools
are designed for average cutting forces, the tools fail prematurely. To understand why this
occurs, it is seen in this project it is due to the high magnitude impact force that comes on
tool at the instance of cutting as shown in figure 6.1.
Fig. 6.1 Schematic sketch of the impact force coming onto the shaper tool at the instance
of cutting.
It is impossible to measure the actual impact force coming on the shaper tool during
machining process. Since the load acts on the tip of the tool, which is engaged in cutting
action it is impossible to place load cells at that place. Hence using Modal Analysis and
Inverse Force Algorithm the impact force is determined. Using this impact force the life of
the tool is estimated.

6.2 Problem Statement
The aim of this project is to study the response of the tool due to impact loads and
using the Inverse Force Algorithm estimate the impact force coming on it during machining.
Also to estimate the life of the tool during operation at three different depths of cut of
0.5 mm, 1 mm and 1.5 mm considering this impact effect.
6.3 Objective of the Project
The project is divided into three phases
1. The first phase of the project is reviewing the literature on Forward and Inverse
problems, Force as inverse problem and analysis of inverse force identification.
2. The second phase proposes a method of inverse analysis of impact force to measure
the magnitude and location of the impact force acting on the cutting tool of a shaper
and obtain the Frequency Response Function (FRF) curves.
3. The third phase of the project proposes a method to estimate the magnitude of the
impact force coming on to the tool during machining using the FRFs and developing
the Inverse Force Algorithm. With the knowledge of this actual impact force, the tool
life is estimated.
6.4 Working Method
With the advent of fast computers, analysing responses of structures has been
simplified. Softwares like LabVIEW and MATLAB have emerged as significant tool for
extraction, storing and analysing the structural responses. The purpose of this study is to
analyse the responses of the shaper tool during machining operation. The FRF data is
collected for the known force and acceleration. The best FRFs are used to determine the
actual cutting force using inverse force algorithm. The experimental results are validated with
results obtained from theoretical relations and the life of the tool is determined and compared
for theoretical and experimental force magnitudes.

6.5 Methodology Steps
1. This study is carried using a 12 × 12 × 150 mm thick HSS shaper tool and the force
coming onto it during machining is predicted.
2. The tool is held firmly into a bench vice and piezoelectric accelerometer is mounted
on the tool using the bee wax at 20mm from the tool tip.
3. NI DAQ (CDAQ 9234) consisting of four channels is installed and connected to a
laptop which is installed with National Instrument’s LabVIEW software.
4. The accelerometer and an impact hammer are connected to two channels.
5. A circuit diagram is drawn in the LabVIEW software to display and store the force
and acceleration data for the time span of 3 seconds.
6. The tool tip is impacted manually using the impact hammer and with a sample size of
30,000 force and acceleration data are stored in lvm file
7. An algorithm to determine FRF curve and store this data as H file is written in
MATLAB.
8. The tool with accelerometer onto it is now mounted onto the shaper machine whose
all parameters like speed and stroke length are fixed.
9. A 5 mm thick work-piece made of mild steel is held firmly in between the shaper
vice.
10. The machine is switched on and tool impacts the work-piece at the depth of cut of 0.5
mm making the accelerometer sense the tool responses.
11. A set of 30,000 acceleration samples for time span of 3 seconds are stored in lvm file
using LabVIEW software.
12. Using the Inverse Force Algorithm in MATLAB which takes this acceleration data
and previously obtained FRF data the impact force is determined.
13. The procedure is carried out for depths of cut of 1mm and 1.5 mm
14. The force obtained is compared using the theoretically obtained force and tool life is
estimated and compared for both experimental and theoretical force.

Chapter 7
EQUIPMENTS USED IN THE EXPERIMENTATION
The equipments that are being used for my experimentation are impact hammer,
accelerometer, and LabVIEW software. A brief description of what each of them is discussed
below.
7.1 Impact Hammer
Fig. 7.1 Impact Hammer used to excite the vibrations [18]
An ideal impact to a structure is a perfect impulse, which has an infinitely small

duration, causing constant amplitude in the frequency domain; this would result in all modes
of vibration being excited with equal energy [18]. The impact hammer test is designed to
replicate this; however, in reality a hammer strike cannot last for an infinitely small duration,
but has a known contact time. The duration of the contact time directly influences the
frequency content of the force, with a larger contact time causing a smaller range of
bandwidth. A load cell is attached to the end of the hammer to record the force. Impact
hammer testing is ideal for small light weight structures; however as the size of the structure
increases issues can occur due to a poor signal to noise ratio. This is common on large civil
engineering structures.

The response curves of impact hammer depend on the type of tip used. Figure 7.2
describes the different response curves, when the tip hardness varies from super soft tip to
hard tip.
Fig. 7.2 Impact Hammer Response Curves [18].
7.2 Accelerometer
An accelerometer is a device that measures proper acceleration. It sees the

acceleration associated with the phenomenon of weight experienced by any test mass at rest
in the frame of reference of the accelerometer device.
Accelerometers have multiple applications in industry and science [19]. Highly

sensitive accelerometers are components of inertial navigation systems for aircraft and
missiles. Accelerometers are used to detect and monitor vibration in rotating machinery.
Accelerometers are used in tablet computers and digital cameras so that images on screens
are always displayed upright. Accelerometers are used in drones for flight stabilisation.

Application of accelerometers in this project is to sense the acceleration of the cutting

tool when it is impacted to the workpiece. The sensed acceleration response is used to
estimate the impact force coming to the tool using modal analysis. Figure 7.3, shows a
schematic diagram of an accelerometer.
Fig. 7.3 Depiction of few piezoelectric accelerometers [19].
7.2.1 Methods of Accelerometer Mounting
The accelerometer is mounted onto the structure whose response is to be measured. In

this case it is mounted on the tool. There are different methods of mounting the
accelerometers. i) typical screw mounting, ii) typical adhesive mounting & iii) magnet mount
for ferrous structures. The figures below show different type of accelerometer mountings.
Fig. 7.4 (a) A Typical screw mounts [19]

Using a screw the accelerometer is mounted to the desired surface whose response is
to be measured. The application of a thin layer of silicone grease between the accelerometer
base and the mounting surface also assists in achieving a high degree of intimate surface
contact required for best high-frequency transmissibility.
Fig. 7.4 (b) A Typical Adhesive Mount [19]
Occasionally, mounting by stud or screw is impractical. For such cases, adhesive

mounting offers an alternative mounting method. The use of separate adhesive mounting
bases is recommended to prevent the adhesive from damaging the accelerometer base or
clogging the mounting threads.
Fig. 7.4 (c) Magnetic mounting [19]

Magnetic mounting bases offer a very convenient, temporary attachment to magnetic

surfaces. Magnets offering high pull strengths provide best high-frequency response. Wedged
dual-rail magnetic bases are generally used for installations on curved surfaces, such as motor
and compressor housings and pipes. However, dual-rail magnets usually significantly
decrease the operational frequency range of an accelerometer. For best results, the magnetic
base should be attached to a smooth, flat surface. A thin layer of silicone grease should be
applied between the sensor and magnetic base, as well as between the magnetic base and the
structure. When surfaces are uneven or non-magnetic, steel pads can be welded or epoxied in
place to accept the magnetic base. Use of such a pad ensures that periodic measurements are
taken from the exact same location. This is an important consideration when trending
measurement data.
7.2.2 Accelerometer Specifications:
The table below shows the detailed specifications of the accelerometer used for
measuring the responses due to the impact.
Table 7.1 Detailed specification of accelerometer PCB 352C03 [19]

7.3 DAQ and LabVIEW Software
The DAQ and LabVIEW software together constitute the system for analysis [20]. In
this bit we see in detail the following:
1. DAQ (Data Acquisition)

2. DAQ device / hardware
3. Advantages of NI DAQ
4. Physical input/ output signals
5. Introduction to LabVIEW Software
7.3.1 DAQ (Data Acquisition)

The purpose of data acquisition is to measure an electrical or physical phenomenon such
as voltage, current, temperature, pressure, or sound. PC-based data acquisition uses a
combination of modular hardware, application software, and a computer to take
measurements. While each data acquisition system is defined by its application requirements,
every system shares a common goal of acquiring, analyzing, and presenting information.
Data acquisition systems incorporate signals, sensors, actuators, signal conditioning, data
acquisition devices, and application software.
So summing up, Data Acquisition is the process of:
• Acquiring signals from real-world phenomena
• Digitizing the signals
• Analyzing, presenting and saving the data
Fig. 7.5 Process of data acquisition [20]

The parts are:
• Physical input/output signals
• DAQ device/hardware
• Driver software
• Your software application (Lab VIEW)
7.3.2 DAQ Device / Hardware

DAQ hardware acts as the interface between the computer and the outside world. It primarily
functions as a device that digitizes incoming analog signals so that the computer can interpret
them.
A DAQ device (Data Acquisition Hardware) usually has these functions:
• Analog input
• Analog output
• Digital I/O
• Counter/timer
Figure 7.6 shows the NI DAQ used to conduct the experiment
Fig. 7.6 NI DAQ (CDAQ 9234) used for data acquisition process

7.3.3 About NI DAQ

The National Instruments 9233 and 9234 are four-channel dynamic signal acquisition
modules for making high-accuracy measurements from IEPE sensors [21]. The NI 9233 and
9234 C Series analog input modules deliver 102 dB of dynamic range and incorporate IEPE
(2 mA constant current) signal conditioning for accelerometers and microphones. The four
input channels simultaneously acquire at rates from 2 to 50 kHz or, with the NI 9234, up to
51.2 kS/s. In addition, the modules include built-in antialiasing filters that automatically
adjust to your sampling rate. Compatible with a single-module USB carrier and NI
CompactDAQ and CompactRIO hardware, the NI 9233 and 9234 are ideal for a wide variety
of mobile/portable applications such as industrial machine condition monitoring and in-
vehicle noise, vibration, and harshness testing.
The NI 9233 and 9234 use a method of A/D conversion known as delta-sigma
modulation [21]. If, for example, the data rate is 25 kS/s, then each ADC actually samples its
input signal at 3.2 MS/s (128 times the data rate) and produces samples that are applied to a
digital filter. This filter then expands the data to 24 bits, rejects signal components greater
than 12.5 kHz (the Nyquist frequency), and digitally resamples the data at the chosen data
rate of 25 kS/s. This combination of analog and digital filtering provides an accurate
representation of desirable signals while rejecting out-of-band signals. The built-in
antialiasing filters automatically adjust themselves to discriminate between signals based on
the frequency range, or bandwidth, of the signal.
The NI Hi-Speed USB carrier makes portable data acquisition easy. NI 9233 or 9234
is plugged into the USB carrier and data is acquired. Communication to the USB carrier is
over Hi-Speed USB, guarantees data transfer throughout.
7.3.4 Advantages of NI DAQ

Designed for performance, NI data acquisition devices provide high-performance I/O,
industry-leading technologies, and software-driven productivity gains for your application.
With patented hardware and software technologies, National Instruments offers a wide-
spectrum of PC-based measurement and control solutions that deliver the flexibility and
performance that your application demands. For more than 25 years, National Instruments

has served as more than just an instrument vendor, but as a trusted advisor to engineers and
scientists around the world.
1. High -Performance I/O: Measurement accuracy is arguably one of the most important
considerations in designing any data acquisition application. Yet equally important is
the overall performance of the system, including I/O sampling rates, throughput, and
latency. For most engineers and scientists, sacrificing accuracy for throughput
performance or sampling rate for resolution is not an option. National Instruments
wide selection of PC-based data acquisition devices have set the standard for
accuracy, performance, and ease-of-use from PCI to PXI and USB to wireless.
2. High-Accuracy Designs: Many scientists and engineers mistakenly evaluate DAQ

device error by just considering the bit resolution of the DAQ device. However, the
error dictated by the device resolution, or quantization error, might account for only a
very small amount of the total error in your measurement result. Other types of errors,
such as temperature drift, offset, gain, and non-linearity can vary drastically by
hardware design. Through years of experience, NI has developed several key
technologies to minimize these errors and maximize the absolute accuracy of your
measurements.
3. Easy Sensor Connectivity with Integrated Signal Conditioning: Traditionally,

measuring sensors required separate front-end signal conditioning systems cabled to a
data acquisition system. New technologies and miniaturization have enabled the
integration of sensor-specific signal conditioning and analog to digital conversion on
the same device. NI DAQ devices with integrated signal conditioning deliver higher-
accuracy measurements by eliminating error-prone cabling and connectors and reduce
the number of components in a measurement system. NI has also partnered leading
sensor vendors to provide easy, tool-free sensor connectivity and automatic sensor
configuration with TEDS technology.
7.3.5 Physical Input/ Output Signals

Data acquisition involves gathering signals from measurement sources and digitizing the
signal for storage, analysis, and presentation on a PC. Data acquisition (DAQ) systems come
in many different PC technology forms for great flexibility when choosing your system.

Scientists and engineers can choose from PCI, PXI, PCI Express, PXI Express, PCMCIA,
USB, Wireless and Ethernet data acquisition for test, measurement, and automation
applications.
There are five components to be considered when building a basic DAQ system
• Transducers and sensors
• Signals
• Signal conditioning
• DAQ hardware
• Driver and application software

Table 7.1 shows the input characteristics of NI DAQ 9234
Table 7.2 Input characteristics of NI CDAQ 9234

7.3.6 Introduction to LabVIEW Software

LabVIEW (short for Laboratory Virtual Instrumentation Engineering Workbench) is
a platform and development environment for a visual programming language from National
Instruments [22]. The graphical language is named "G". Originally released for the Apple
Macintosh in 1986, LabVIEW is commonly used for data acquisition, instrument control, and
industrial automation on a variety of platforms including Microsoft Windows, various flavors
of UNIX, Linux, and Mac OS X. The code files have the extension “.vi”, which is an
abbreviation for “Virtual Instrument”. LabVIEW offers lots of additional Add-Ons and
Toolkits.
1. Dataflow programming: The programming language used in LabVIEW, also referred
to as G, is a dataflow programming language. Execution is determined by the
structure of a graphical block diagram (the LV-source code) on which the
programmer connects different function-nodes by drawing wires. These wires
propagate variables and any node can execute as soon as all its input data become
available. Since this might be the case for multiple nodes simultaneously, G is
inherently capable of parallel execution. Multi-processing and multi-threading
hardware is automatically exploited by the built-in scheduler, which multiplexes
multiple OS threads over the nodes ready for execution.
2. Graphical programming: LabVIEW ties the creation of user interfaces (called front
panels) into the development cycle. LabVIEW programs/subroutines are called virtual
instruments (VIs). Each VI has three components: a block diagram, a front panel, and
a connector panel. The last is used to represent the VI in the block diagrams of other,
calling VIs. Controls and indicators on the front panel allow an operator to input data
into or extract data from a running virtual instrument. However, the front panel can
also serve as a programmatic interface. Thus a virtual instrument can either be run as
a program, with the front panel serving as a user interface, or, when dropped as a node
onto the block diagram, the front panel defines the inputs and outputs for the given
node through the connector pane. This implies each VI can be easily tested before
being embedded as a subroutine into a larger program.
The graphical approach also allows non-programmers to build programs

simply by dragging and dropping virtual representations of lab equipment with which

they are already familiar. The LabVIEW programming environment, with the
included examples and the documentation, makes it simple to create small
applications. This is a benefit on one side, but there is also a certain danger of
underestimating the expertise needed for good quality "G" programming. For
complex algorithms or large-scale code, it is important that the programmer possess
an extensive knowledge of the special LabVIEW syntax and the topology of its
memory management. The most advanced LabVIEW development systems offer the
possibility of building stand-alone applications. Furthermore, it is possible to create
distributed applications, which communicate by a client/server scheme, and are
therefore easier to implement due to the inherently parallel nature of G-code.
The application of LabVIEW in this project is to measure the response of the

accelerometer due to the impact force. The figure 7.6 shows the circuit for data acquisition of
force and acceleration.
Fig. 7.7 A typical LabVIEW Circuit used for Data Acquisition of force and acceleration.

Chapter 8
EXTRACTION OF FREQUENCY RESPONSE

FUNCTION (FRF)
The project is divided into 3 phases. In the first phase the problem statement was
framed. It states that “Estimation of life of the cutting tool of the shaper with the knowledge
of actual cutting forces”. Also in this phase all the prerequisite materials and equipments
needed for the project was arranged.
The second phase of the project included in collection of FRF data for the estimation
of the cutting force. The acceleration and the impact force history were collected and FRF
data was obtained. Figure 8.1 shows the experimental setup to determine the FRF of the
cutting tool.
Fig. 8.1 Experimental setup to determine the FRF of the cutting tool.
The cutting tool was mounted in the vice. Location points were marked on it with
equal distance of 20mm between them. An accelerometer was placed at location 2 and impact
hammer was hammered at location 1 i.e. on the tip of the tool and the data was collected for 3

seconds. 30,000 values of acceleration and impact force each were obtained in the span of 3
seconds.
The LabVIEW circuit diagram and the output obtained is as shown in figure 8.2 and
8.3 respectively
Fig. 8.2 LabVIEW circuit constructed for acquiring signals for the fixed duration of 3
seconds
Fig. 8.3 The output of the LabVIEW program displaying force and acceleration data for
time span of 3 seconds

The program was written using MATLAB software to obtain the FRF data. The
output data of this program is as below.
Fig. 8.4 Acceleration and Impact force data in time domain.
This time domain data is converted into frequency domain data using Fast Fourier
Transforms (FFT) and the Frequency Response Function (FRF) curve is obtained as shown in
figure 8.5
Fig. 8.5 FRF curve for the above data

Similarly another data is collected for same position of accelerometer at location 2

and impacted at location 1 and the data obtained is as below.
Fig. 8.6 Acceleration and Impact force data in time domain.
Fig. 8.7 FRF curve for the data obtained in figure 8.6
Similarly 75 sets of FRFs were collected out of which 11 best FRFs were chosen to be
used in the prediction of the impact force coming onto the cutting tool at different depths of
cut.

Chapter 9
ESTIMATION OF IMPACT FORCE
The final phase of the project deals with estimation of the impact force magnitude
when the cutting tool impacts the work piece at three different depths of cut (DOC) of
0.5mm, 1mm and 1.5 mm respectively. Also during experimentation it was seen that at
approximately 1.8 mm depth of cut due to the impact force the cutting tool failed. The force
magnitude measured is 140N. Thus it is clear that the tool can withstand maximum force of
140N. The tool life is thus estimated for this force.
The experiment in this phase is carried out by mounting the tool over the shaper
machine holding it firmly in the tool holder as shown in the photograph.
Fig. 9.1 Position of the cutting tool in the tool holder of shaper machine
The accelerometer is mounted at a distance of 20mm from the tool tip as shown in the
above figure. The workpiece is of mild steel material and is 5mm thick. The shaper machine
is set at constant speed of 17 strokes per minute (SPM) and the experiment is carried out.

Using the LabVIEW software the acceleration due to impact data is collected for a time span
of 3 seconds.
Acceleration data for 0.5mm depth of cut: The shaper head is set to the depth of cut of
0.5mm using the scale provided. When the machine is started and the program is also
executed simultaneously. The tool comes and impacts the work piece that causes vibration of
the tool. This vibration is sensed by the accelerometer mounted on the tool. In the span of 3
seconds, 30,000 acceleration amplitudes are recorded. An Inverse Force Algorithm to
estimate the force that causes this acceleration is written using MATLAB software. The
algorithm takes reference of the H matrix from the previously obtained FRF data and FFA
data of the acceleration due to impact and predicts the unknown cutting force. The cutting
force is predicted using the best FRFs sets collected from different sets of impacts and the
corresponding acceleration responses. This is called as inverse method of force estimation.
Below is the FRF curve whose data is used to estimate the cutting force at depth of
cuts of 0.5 mm, 1 mm, 1.5mm.
.
Fig. 9.2 FRF curve used to predict the cutting force

The output of the algorithm that predicts the cutting force that is required at the depth
of cut of 0.5 mm for 3 sets of impacts using a single best FRF above is shown in figure 9.3 (a,
b, c).
Fig. 9.3 (a) Predicted force at the depth of cut of 0.5mm for 1st Impact
Fig. 9.3 (b) Predicted force at the depth of cut of 0.5mm for 2nd Impact
Fig. 9.3 (c) Predicted force at the depth of cut of 0.5mm for 3rd Impact

Similarly the output of the algorithm that predicts the cutting force that is required at
the depth of cut of 1 mm for 3 sets of impacts using a single best FRF from figure 9.2 is
shown in figure 9.4 (a, b, c).
Fig. 9.4 (a) Predicted force at the depth of cut of 1mm for 1st Impact
Fig. 9.4 (b) Predicted force at the depth of cut of 1mm for 2nd Impact
Fig. 9.4 (c) Predicted force at the depth of cut of 1mm for 3rd Impact

Similarly the output of the algorithm that predicts the cutting force that is required at
the depth of cut of 1.5 mm for 3 sets of impacts using a single best FRF from figure 9.2 is
shown in figure 9.5 (a, b, c).
Fig. 9.5 (a) Predicted force at the depth of cut of 1.5 mm for 1st Impact
Fig. 9.5 (b) Predicted force at the depth of cut of 1.5 mm for 2nd Impact
Fig. 9.5 (c) Predicted force at the depth of cut of 1.5 mm for 3rd Impact

These results obtained were compared with the results obtained in the paper titled
“Estimation of Impact Effect on the Cutting Tool of a Shaper from Measurement of
Responses during Machining” by Shrinivas L. Gombi et al [8] and they match with ± 1%
error.
For the depth of cut of 1mm to verify the consistency of FRFs, for a single impact the
algorithm predicted the same force using different FRFs. The figures 9.6 (a, b, c) show three
different FRFs used.
Fig. 9.6 (a) FRF Curve 1 used to predict the cutting force
Fig. 9.6 (b) FRF Curve 2 used to predict the cutting force
Fig. 9.6 (c) FRF Curve 3 used to predict the cutting force

The force for the single impact 1.413 seconds, the above FRFs predicted the
same force with ± 1% error as shown in figure 9.7 (a, b, c)
Fig. 9.7 (a) Force predicted by the algorithm using FRF data from figure 8.6 (a)
Fig. 9.7 (b) Force predicted by the algorithm using FRF data from figure 8.6 (b)
Fig. 9.7 (c) Force predicted by the algorithm using FRF data from figure 8.6 (c)

Further the experiment was extended to obtain the result for 1.8 mm depth of cut for
same speed and stroke length, and it was found that that the tool failed at 138.6N of impact
force. Also multiple impacts were recorded due to instability in the cutting. The output of the
inverse force algorithm for determining this failure force is as shown below.
Fig. 9.8 Predicted failure force at the depth of 1.8mm with multiple impacts.

Chapter 10
THEORETICAL CUTTING FORCE MAGNITUDE
AND ESTIMATION OF THE TOOL LIFE
Tool life can be estimated by conventional Taylor’s tool life equation as [16]:
VcTn = C (10.1)
More general form of the equation is [16]
VcTn × dxsy = C (10.2)
Where Vc = Cutting Speed
Tn = Tool Life
d = Depth of Cut
s = Feed rate
x and y are steel constants
n and C are constants found by experimentation; they are properties of tool
material, workpiece and feed rate.
Other method incorporated in this project is by calculating the theoretical force given
by the equation [23]:
Fc = 9.807 × Cp × k × dx × sy (10.3)
Where Cp, k, x, and y are the steel constants, d is the depth of cut and s is feed in cm.
For steels
Cp = 40 to 80, so considering mid-value we take Cp = 60
k=1
x = 0.86
y = 0.74
Tool life is found by using Goodman equation and Miner’s method.
The theoretical cutting force is calculated using above equation for depths of cut of
0.5 mm, 1 mm, 1.5 mm and 1.8 mm. The life of tool is compared for theoretical cutting force
and the experimentally obtained cutting force at these depths of cut.

10.1 Tool life at 0.5 mm Depth of Cut

1. Theoretical cutting force calculation is given by the equation 10.1 [23]
Fc = 9.807 × Cp × k × dx × sy
For steels
k=1
x = 0.86
y = 0.74
And feed s = 0.06 cm
Substituting these in above equation for depth of cut of 0.5mm
Fc = 9.807 × 60 × 1 × 0.50.86 × 0.060.74
Fc = 40.423 N
The above obtained force is the average cutting force that is obtained theoretically.
The force is said to be average because of various material constants are assumed for the
calculation.
2. Prediction of tool life for the experimentally obtained cutting force.

For the depth of 0.5 mm it was observed that the impact force is equal to 97.32 N.
Fig. 10.1 CAD model of the tool showing cross section area of the tool at plane 0.5 mm
from the tool tip.

The cross sectional area of the tool at 0.5 mm from the tip is A = 0.872 mm2
Shear stress due to this force is τ = F/A = 97.32 / 0.872 = 111.6 MPa
We know that shear stress is 0.6 times the normal stress. Thus we have
σa = τ / 0.6 = 111.6 / 0.6 = 186 MPa.
The tool material is M42 High Speed Steel (HSS).
Ultimate tensile strength for M42 HSS = 640 MPa to 2000MPa. Therefore taking
average we have Su = 1320 MPa.
Yield strength for M42 HSS = σy = 700MPa
From Goodman equation [24] we have.

+ =
Where n = Factor of Safety = σy / σa = 700 / 186 = 3.76
σm = σa /2= 93MPa
Substituting for σa, σm, Su and n in above equation and solving we get
Sen = 51.86 MPa
Taking 0.9 × Su = 0.9 × 1320 = 1188 MPa
Using the Miner’s method for life estimation, we can predict the life of the tool in terms
of number of strokes.
Log 0.9 Su = log 1188 = 3.0748
Log Sen = log 51.86 = 1.7148
Log σa = log 77.26 = 1.8879

Fig. 10.2 Miner’s method for predicting tool life for experimentally obtained force of
97.32 N.
From figure 10.2 we have two similar triangles, ∆ABC and ∆DEC
Applying the rule of similar triangles that is sides of two similar triangles are proportional to
each other.
=
!
3.0748 − 1.7148 6 − 3
=
3.0748 − 1.8879 !
Simplifying DE = 5.6182
N = 104.6629= 4, 15, 187.35
Thus the life of the tool for experimentally obtained cutting force of 97.32 N is estimated
to be 4, 15, 187 strokes of the tool.

3. Prediction of tool life for the theoretically obtained cutting force.

The cross sectional area of the tool at 0.5 mm from the tip is A = 0.872 mm2
σa = τ / 0.6 = 46.356 / 0.6 = 77.26 MPa.

+ =
Where n = Factor of Safety = σy / σa = 700 / 77.26 = 9.06
σm = σa /2 = 38.63 MPa
Sen = 157.58 MPa
Taking 0.9 × Su = 0.9 × 1320 = 1188 MPa
Log 0.9 Su = log 1188 = 3.0748
Log Sen = log 51.39= 2.1975
Log σa = log 186 = 2.2695

Fig. 10.3 Miner’s method for predicting tool life for theoretically obtained force of
40.423 N.
each other.
=
!
3.0748 − 2.1975 6 − 3
=
3.0748 − 2.2695 !
N = 105.7538= 5, 67, 325.76

Thus the life of the tool for theoretically obtained cutting force of 40.432 N is estimated to be
5, 67, 326 strokes of the tool.

10.2 Tool life at 1 mm Depth of Cut

Fc = 9.807 × Cp × k × dx × sy
For steels
k=1
x = 0.86
y = 0.74
And feed s = 0.06
Substituting these in above equation for depth of cut of 1 mm
Fc = 9.807 × 60 × 1 × 10.86 × 0.060.74
Fc = 73.37 N
calculation.

For the depth of 1 mm it was observed that the impact force is equal to 108.8 N.
Fig. 10.4 CAD model of the tool showing cross section area of the tool at plane 1 mm
from the tool tip.
The cross sectional area of the tool at 1 mm from the tip is A = 1.583 mm2
Shear stress due to this force is τ = F/A = 108.8/ 1.583 = 68.73 MPa
σa = τ / 0.6 = 68.73 / 0.6 = 114.55 MPa.

+ =
Where n = Factor of Safety = σy / σa = 700 / 186 = 3.76
σm = σa /2 = 57.28 MPa
Sen = 73.252 MPa
Taking 0.9 × Su = 0.9 × 1320 = 1188 MPa
Log 0.9 Su = log 1188 = 3.0748
Log Sen = log 73.252= 1.8648
Log σa = log 114.55 = 2.0589

108.8 N.
each other.
=
!
3.0748 − 1.8648 6 − 3
=
3.0748 − 2.0589 !
N = 104.5561= 3, 30, 182.92
Thus the life of the tool for experimentally obtained cutting force of 108.8 N is estimated
to be 3, 30, 183 strokes of the tool.


σa = τ / 0.6 = 46.348 / 0.6 = 77.248 MPa.

+ =
Where n = Factor of Safety = σy / σa = 700 / 77.248 = 9.06
σm = σa /2 = 38.624 MPa
Sen = 52.03 MPa
Taking 0.9 × Su = 0.9 × 1320 = 1188 MPa
Log 0.9 Su = log 1188 = 3.0748
Log Sen = log 55.03 = 1.7406
Log σa = log 77.248 = 1.8879

Fig. 10.6 Miner’s method for predicting tool life for theoretically obtained force of 73.37
N.
each other.
=
!
3.0748 − 1.7406 6 − 3
=
3.0748 − 1.8897 !
N = 105.6182 = 4, 62, 132.16
Thus the life of the tool for theoretically obtained cutting force of 73.37 N is estimated to
be 4, 62, 132 strokes of the tool.


Fc = 9.807 × Cp × k × dx × sy
For steels
k=1
x = 0.86
y = 0.74
And feed s = 0.06
Substituting these in above equation for depth of cut of 1 mm
Fc = 9.807 × 60 × 1 × 1.50.86 × 0.060.74
Fc = 103.98 N
calculation.

Fig. 10.7 CAD model of the tool showing cross section area of the tool at plane 1.5 mm
from the tool tip.
σa = τ / 0.6 = 58.02 / 0.6 = 96.703 MPa.

+ =
Where n = Factor of Safety = σy / σa = 700 / 96.703 = 7
σm = σa/2 = 48.352 MPa
Sen = 52.69 MPa
Taking 0.9 × Su = 0.9 × 1320 = 1188 MPa
Log 0.9 Su = log 1188 = 3.0748
Log Sen = log 52.69= 1.7218
Log σa = log 85.919 = 1.9341

117.03 N.
each other.
=
!
3.0748 − 1.7218 6 − 3
=
3.0748 − 1.9341 !
N = 105.5292 = 3, 38, 251.82

Thus the life of the tool for experimentally obtained cutting force of 117.03 N is
estimated to be 3, 38, 252 strokes of the tool.


σa = τ / 0.6 = 51.552 / 0.6 = 85.919 MPa.

+ =
σm = σa /2 = 42.96 MPa
Sen = 64.68 MPa
Taking 0.9 × Su = 0.9 × 1320 = 1188 MPa
Log 0.9 Su = log 1188 = 3.0748
Log Sen = log 64.68= 1.8108
Log σa = log 96.703= 1.9854

103.98 N.
each other.
=
!
3.0748 − 1.8108 6 − 3
=
3.0748 − 1.9854 !
N = 104.6934= 3, 85, 138.05
Thus the life of the tool for theoretically obtained cutting force of 103.98 N is estimated
to be 3, 85,138 strokes of the tool.


Fc = 9.807 × Cp × k × dx × sy
For steels
k=1
x = 0.86
y = 0.74
s = 0.06
Substituting these in above equation for depth of cut of 1.8mm
Fc = 9.807 × 60 × 1 × 1.80.86 × 0.060.74
Fc = 121.633 N
calculation.

For the depth of 1.8mm it was observed that the impact force is equal to 138.6N.
The cross sectional area of the tool at 1.8mm from the tip is A = 2.328mm2
Fig. 10.10 CAD model of the tool showing cross section area of the tool at the plane
1.8 mm from the tool tip.

σa = τ / 0.6 = 59.587 / 0.6 = 99.312MPa.

+ =
σm = σa/2 = 49.66 MPa
Sen = 48.767 MPa
Taking 0.8 × Su = 0.9 × 1320 = 1188 MPa
Log 0.9 Su = log 1188 = 3.0748
Log Sen = log 48.767 = 1.6881
Log σa = log 87.079 = 1.9399

138.6 N.
each other.
=
!
3.0748 − 1.6881 6 − 3
=
3.0748 − 1.9399 !
N = 105.4553= 2, 85, 321.96
Thus the life of the tool for experimentally obtained cutting force of 138.6 N is estimated to
be 2, 85, 322 strokes of the tool.


For the depth of 1.8mm it was observed that impact force is equal to 121.633 N.
Thus Fc = 121.633 N
The cross sectional area of the tool at 1.8mm from the tip is A = 2.328mm2
σa = τ / 0.6 = 53.248 / 0.6 = 87.079 MPa.

+ =
σm = σa/2 = 43.54 MPa
Sen = 61.568 MPa
Taking 0.9 × Su = 0.9 × 1320 = 1188 MPa
Using the Miner’s method for life estimation, we can predict the life of the tool in
terms of number of strokes.
Log 0.9 Su = log 1188 = 3.0748
Log Sen = log 61.568 = 1.7894
Log σa = log 99.312 = 1.9970

121.663 N.
Applying Miner’s method for predicting tool life for theoretically obtained force of
121.663 N.the rule of similar triangles that is sides of two similar triangles are proportional to
each other.
=
!
3.0748 − 1.7894 6 − 3
=
3.0748 − 1.9970 !
N = 105.5154 = 3, 27, 642.32
Thus the life of the tool for theoretically obtained cutting force of 121.663 N is
estimated to be 3, 27, 642 strokes of the tool.
Chapter 11
RESULTS AND DISCUSSIONS

The cutting force is predicted using the best FRFs sets collected from different sets of
impacts and the corresponding acceleration responses. A very good consistency in the
predicted magnitude of the impact force is observed with each combination of FRF was used.
The estimated impact forces from the developed force identification algorithm has
been validated by comparing with the force magnitudes of obtained by Shrinivas L. Gombi et
al [8]. The identified cutting force is in very close agreement with the measured force within
a range of ± 1% error as shown in table 11.1.
Table 11.1 Comparison of experimentally obtained cutting force with predicted cutting
force at different depths of cut.
Depth
Three sets of Experimentally obtained Predicted cutting Percentage
of Cut
cutting force in N force in N [8] Error
in mm
0.5 96.99 97.03 97.98 98 0.98996%
1 108.4 109.3 108.8 108 0.9963%
1.5 117.4 116.6 117.1 118 0.9949%
The experiment is conducted at depth of cut of 1mm for impact occurring at 1.413
seconds. It is observed that 3 different FRF data are consistent enough to predict the cutting
force of 108.8 N, 108.2 N and 109.1 N.
Further when the experiment is extended to 1.8 mm depth of cut it is seen that the tool
failure occurred at 138.6 N and this force is validated by theoretically calculated average
cutting force which is 121.633 N. This shows that the experimentally obtained force is 1.14
times the theoretically calculated average cutting force.

The theoretical force calculated for each depth of cut is shown in the Table 11.2
below. Also the life of the tool is calculated at each depth of cut.
Table 11.2 Comparison of experimentally obtained cutting force with theoretical cutting
force and tool life for each at different depths of cut.
Cutting Force in N Tool Life in Strokes %

Depths Difference
Reduction
of Cut in tool life
in tool
in mm Theoretical Experimental Theoretical Experimental in strokes
life
0.5 40.423 97.32 5, 67, 326 4, 15, 187 1, 52, 139 26.817 %
1 73.37 108.8 4, 62, 132 3, 30, 183 1, 31, 949 28.552 %
1.5 103.98 117.03 3, 85, 138 3, 38, 252 46, 886 12.174 %
1.8 121.633 138.6 3, 27, 642 2, 85, 322 42, 320 12.917 %

CONCLUSION
Unlike static force analysis, dynamic force analysis is a complex task. But with the
help of modal analysis it is simple to obtain the Frequency Response Function for a pair of
dynamic force and acceleration caused due to it. Using this consolidated data the actual
impact force magnitude can be measured.
For a shaper tool it is difficult to place the load cells or any force measuring device in
between the tool tip and the workpiece as the cutting action makes it impossible to place any
device in between the tool tip and workpiece. For measuring the impact force acting on the
cutting tool under this condition we implement the inverse force measuring technique. Modal
analysis and FRF data help in obtaining the magnitude of the actual cutting force. Using this
actual cutting force and considering the impact effect, actual tool life is calculated.
Observing the experimental force we can say that it is 1.14 times the theoretical force
which is the average cutting force. It is seen from the results obtained the life of the tool goes
on reducing as the depth of cut increases. It is thus proved that the life of the tool is
drastically reduced by 1, 52, 139 strokes of the tool for depth of cut of 0.5 mm that is it is
reduced by 26.817% and for the depth of cut of 1.8 mm the life of the tool is reduced by
12.917 % that is when calculated using the experimentally obtained cutting force. This is due
to the impact effect of tool on the work piece at the instance of cutting.

REFERENCES
[1] David V. Hutton, “Fundamentals of Finite Element Analysis”, Elizabeth A. Jones, Mc

Graw Hill Higher Education, Edition 1, 2004.
[2] N. Okubo, S. Tanabe and T. Tatsuno, “Identification of forces generated by a machine
under operating conditions”, Proceedings of the third International Modal Analysis
Conference, 1997, pp.920-927
[3] Uhl, T., Mendrok.K, “Inverse Identification Problems: Theory and Practical
Applications.” 2003, ITE Press, Krakow.
[4] G.R. Liu, X. Han “Computational Inverse Techniques in Non-destructive Evaluation”,
CRC Press LCC, 2003.
[5] K. K. Stevens, “Force Identification Problems-an overview”, Proceedings of the SEM
spring conference on Experimental Mechanics, Houston, Texas, USA, 1987, pp.838-
844.
[6] Whiston, G.S., “Remote Impact Analysis by use of propagated Acceleration signals,
2: Comparison between Theory and Experiment,” Journal of Sound and Vibration,
Vol.97, No.1, 1984, pp.36-51.
[7] M. T. Martin and J. F. Doyle, “Impact Force Identification from Wave Propagation
Responses,” Journal of Impact Engineering, Vol.18, No.1, 1996, pp.65-77.
[8] Bor-Tsuen Wang, Kuan-Yuan Lin, “Prediction of Harmonic Force Acting on
Cantilever Beam”, Proceedings of the 22nd International Modal Conference,
Dearborn, Michigan, Paper No. 64, Session 3. 2004
[9] Shrinivas L. Gombi and Dr. D. S. Ramakrishna, “Estimation of Impact effect on The
Cutting Tool of A Shaper from Measurement of Responses During
Machining.” Journal for Manufacturing Science & Production. Volume 12, Issue 3-4,
Dec 2012, pp.161–169.
[10] Brian J. Schwarz and Mark h. Richardson, “ Experimental Modal Analysis,” CSI
Reliability Week, Orlando, FL, Oct 1999, pp.1-12
[11] Wager J. G., Barash M. M., “Study cf the Distribution of the Life of HSS Tools”,
Transactions of the ASHE,November 1971, pp.1044-1050.

[12] P.N. Botsaris and J.A. Tsanakas, “State-Of-The-Art in Methods Applied to Tool
Condition Monitoring (TCM) in Unmanned Machining Operations: A Review.” E-
Proceedings of the International Conference of COMADEM, Prague, 2008, pp. 73-87.
[13] Peter Avitabile, “Experimental Modal Analysis - A Simple Non-Mathematical
Presentation,” Sound and Vibration magazine, Jan 2001.
[14] J.C.A. Barata, M. S. Hussein, “The Moore-Penrose Pseudoinverse- A tutorial review
of the theory”, arXiv: 1110.6882v1 [Math-ph] 31 Oct 2011.
[15] Pradeep Patokar, Sunil Andhale, Chinmay Patil, Nitin Borkar, “Methods to Improve
Production Rate in Turning Operation,” International Journal of Research in Advent
Technology, Vol.2, No.3, March 2014
[16] P. C. Sharma, “A Textbook of Production Engineering,” S. Chand Publication,
Edition 10, ISBN: 81-219-0111-1, 2011.
[17] Manuf J. “Magnetic Field Effects in Machining Processes and on Manufactured Part
Mechanical Characteristics”, Journal of Manufacturing Science and Engineering, Vol.
128, Issue 1.
[18] Bentely Nevada* Asset Condition Monitoring, “Modal Impact Hammer,”
Specification and Ordering Information, General Electronics.
[19] John Kubler, “Selecting Accelerometers for Modal Analysis,” Kistler Instrument
Corporation, IMAC XXVI, Orlando, Feb 6 2008
[20] LabVIEW User Manual, National Instruments, April 2003 Edition.
[21] NI CDAQ 9233 - 9234 User Manual and Product Specification, National Instruments,
Technical Sales, United States, Revised: 2010-11-03.
[22] Hans-Petter Halvorsen, “Introduction to LabVIEW”, Department of Electrical
Engineering, Information Technology and Cybernetics, Telemark University College,
Faculty of Technology, 20 April 2012
[23] S. K. Basu, “Design of Machine Tools”, Oxford & IBH Publishing, 5th Edition, Jan 1
2008, pp 30-36
[24] H. G. Patil, “Machine Design Data Handbook”, Shree Shashi Prakashan, 3rd Edition,
Nov 2000. Pp 27-40
[25] V B Bhandari, “Design of Machine Elements”, 2nd Edition, Tata McGraw - Hill
Education, 2007

PUBLICATION
INTERNATIONAL CONFERENCE
[1] Dr. Shrinivas L. Gombi, Akhil A. Deshpande, “Redesign of component sizes of a
machine tool using inverse identification of operating cutting force”, Proceedings of
International Conference on Innovations and Emerging Trends in Mechanical
Engineering, held on 13th June 2014, Nagarjuna College of Engg & Tech, Devanahalli,
Bangalore, India.

APPENDIX
Frequency Response Curves extracted during experimentation
Below are the other Frequency Function Curves that have been extracted. Using these
FRF curves also the same force magnitude at 0.5 mm, 1 mm, 1.5mm and 1.8mm each
can be obtained.


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ESTIMATION OF LIFE OF THE CUTTING TOOL WITH THE KNOWLEDGE OF

Thesis · July 2014

Akhil Aneel Deshpande

Application of Identified Inverse Forces in Structures View project

The user has requested enhancement of the downloaded file.

In partial fulfilment of requirements for the award of degree of

Under The Guidance Of

KARNATAK LAW SOCIETY’S

“Gratitude is the memory of heart”

I express my sincere gratitude to Principal, Dr. A. S. Deshpande for providing the

I am greatly obliged to Dr. Shrinivas L. Gombi, HOD of Mechanical Engineering for

I am immensely indebted to all the teaching and non-teaching staff of Department of

Chapter 2: Literature Review 03

2.1: Forward and Inverse Problems 03

2.2: Force Identification as an Inverse Problem 03

2.3: Analysis of Impact Force Identification 04

2.4: Tool Life and Condition Monitoring 05

2.5: Summary of Literature Review 06

Chapter 3: Forward and Inverse Problems 07

3.1: Force Identification as an Inverse Problem 08

Chapter 4: Analysis of inverse Force Identification 11

4.1: Time Domain Analysis 11

4.2: Frequency Domain Analysis 12

4.3: Frequency Response Function (FRF) 15

Chapter 5: Factors affecting Tool Life 16

5.1: Cutting Force 16

5.2: Cutting Speed 17

5.4: Tool Geometry 17

5.5: Tool Material 17

5.6: Work material 18

5.7: Cutting Fluid 18

5.8: Tool Wear 18

5.9: Presence of Magnetic Field 19

Chapter 6: Problem Definition 20

6.1: Problem Description 20

6.2: Problem Statement 21

6.3: Objective of the Project 21

6.4: Working Method 21

6.5: Methodology Steps 22

Chapter 7: Equipments used in the Experimentation 23

7.1: Impact Hammer 23

7.2.1: Methods of Accelerometer Mounting 25

7.3: DAQ and LabVIEW Software 28

7.3.1: DAQ (Data Acquisition) 28

Chapter 9: Estimation of Impact Force 39

Chapter 11: Results and Discussions 68

Thus, the knowledge of the operating dynamic forces is an essential requirement

M.Tech. Machine Design

M.Tech. Machine Design

2.1 Forward and Inverse Problems

2.2 Force Identification as an Inverse Problem

M.Tech. Machine Design

2.3 Analysis of Impact force Identification

M.Tech. Machine Design

2.4 Tool Life and Condition Monitoring

M.Tech. Machine Design

2.5 Summary of Literature Review

The inverse problems need to be well posed or well-conditioned and ill-conditioned

M.Tech. Machine Design

FORWARD AND INVERSE PROBLEMS

Fig. 3.1 Schematic representation of Forward and Inverse Problems [3].

M.Tech. Machine Design