DOI 10.1007/s00170-007-0986-z
ORIGINAL ARTICLE
Received: 13 December 2006 / Accepted: 19 February 2007 / Published online: 23 March 2007
# Springer-Verlag London Limited 2007
1 Introduction
In the last three decades or so, there have been tremendous
improvements and technical revolutions in manufacturing
H. Chelladurai : V. K. Jain (*) : N. S. Vyas
Department of Mechanical Engineering,
Indian Institute of Technology Kanpur,
Kanpur 208016, India
e-mail: vkjain@iitk.ac.in
472
Indirect methods
-Electrical resistance
-Optical measurements
-Radio active
-Contact sensing
473
hf tan a0
1 tan g 0 tan a0
474
3 Experimentation
Experiments were carried out on a CNC Gildemeister CTX
400 Serie 2 turning centre. The experimental setup is shown
in Fig. 4. Experiments were conducted on EN-8 steel using
Rap test
Fundamental
Frequency 3.91 kHz.
0.0025
Acceleration , g
0.0020
Cutting speed
Feed rate
Depth of cut
Flank wear
Unit
m/min
mm/min
mm
mm
Levels
1
200
100
3
0
350
300
4
0.2
500
500
5
0.3
0.0015
0.0010
0.0005
0.0000
0
0.4
0.5
500
1000
1500
2000
2500
3000
Frequency , Hz
3500
4000
4500
5000
475
0.18
0.16
Acceleration, g
0.14
0.12
0.10
0.08
0.06
0.04
0.02
0.00
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
Frequency, Hz
a
0.7
Flank wear = 0.5 mm
0.6
Acceleration , g
0.5
0.4
0.3
0.2
0.1
0.0
2.5
3.0
3.5
4.0
4.5
5.0
Depth of cut , mm
b
0.7
0.6
Flank wear = 0.0 mm
0.5
Acceleration , g
0.0
0
100
200
300
400
500
0.7
0.6
Flank wear = 0.4
Acceleration , g
0.5
Micro strain
0.2
0.1
3
2
0
150
200
250
300
350
400
450
500
0
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
Frequency, Hz
476
a 3.0
a 3.0
2.5
2.0
2.5
1.5
2.0
Micro strain
Acceleration , g
0.5
1.0
0.0
0.5
2.5
3.0
3.5
4.0
4.5
5.0
5.5
Depth of cut , mm
0.0
b 3.0
2.5
3.0
3.5
4.0
4.5
5.0
Depth of cut , mm
2.5
2.0
2.0
Flank wear = 0.3 mm
1.5
Micro strain
Acceleration , g
1.0
1.5
1.0
0.5
0.5
0.0
0
100
200
300
400
500
0.0
c
Flank wear = 0.5 mm
100
150
200
250
300
350
400
450
500
25
2.5
20
Micro strain
Acceleration , g
50
3.0
1.5
1.0
15
10
Flank wear = 0.0 mm
0.5
0.0
150
200
250
300
350
400
450
500
0
150
200
250
300
350
400
450
500
477
0.030
0.030
0.025
0.025
0.020
0.020
Acceleration , g
Acceleration , g
0.015
Experimental
results
0.010
Experimental
results
0.015
0.010
Regression model
results
0.005
0.005
Regression model
results
0.000
2.5
0.000
150
200
250
300
350
400
450
500
3.0
4.5
5.0
0.030
0.025
0.025
0.020
0.020
Acceleration , g
Acceleration , g
4.0
Depth of cut , mm
b 0.030
0.015
Experimental results
0.010
3.5
Regression model
results
0.015
Experimental
results
0.010
Regression model
results
0.005
0.005
0.000
0
100
200
300
400
500
0.000
0.15
0.20
0.25
0.30
0.35
0.40
Flank wear , mm
478
0.030
0.030
0.025
0.025
0.020
Experimental
results
0.015
Regression model
results
0.010
Acceleration , g
Acceleration, g
0.005
0.020
0.015
Regression model
results
0.010
Experimental
results
0.005
0.000
0.000
150
200
250
300
350
400
450
2.5
500
3.0
d
0.030
4.0
4.5
5.0
0.030
0.025
0.020
0.015
Regression model
results
0.010
Experimental results
0.005
Acceleration , g
0.025
Acceleration , g
3.5
Depth of cut , mm
0.020
0.015
Regression model
results
Experimental
results
0.010
0.005
0.000
0.000
0
100
200
300
400
500
0.15
0.2
0.25
0.3
0.35
0.4
Flank wear , mm
479
2 exp a2 x1 b2 x2 c2 x3 d2 x4 e2
where,
exp a3 x1 b3 x2 c3 x3 d3 x4 e3
where, x1= cutting speed, x2= feed rate, x3= depth of cut,
x4= flank wear, 1= acceleration, g in cutting direction, 2=
acceleration, g in feed direction, = micro strain.
a 0.50
Ai
Am
0.5
0.4
0.40
Micro strain
Micro strain
Experimental
0.20
0.3
0.2
Experimental results
0.1
0.10
0
2.5
0.00
150
200
250
300
350
400
450
500
3.0
3.5
4.0
4.5
5.0
Depth of cut , mm
b 0.5
d
0.50
0.4
0.40
Micro strain
Micro strain
0.30
0.20
Regression model results
Experimental results
0.1
0.10
0
0
100
200
300
400
500
0.00
0.15
0.20
0.25
0.30
0.35
0.40
Flank wear , mm
480
100-100-100-100-5
110-110-110-110-5
120-120-120-120-5
125-125-125-120-5
125-125-125-125-5
130-130-130-120-5
130-130-130-125-5
130-130-130-130-5
140-140-130-120-5
140-140-130-125-5
140-140-140-120-5
150-140-130-120-5
150-150-150-120-5
150-150-150-150-5
130-120-120-120-5
120-120-120-120-5
140-130-130-120-5
130-120-120-100-5
130-130-120-120-5
20000
20000
7390
5386
20000
4049
5029
9251
6351
3351
4051
6851
4901
20000
1863
4113
1851
2052
3311
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
Comments
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
logsig,
tansig,
tansig,
tansig,
tansig,
tansig,
tansig,
tansig,
tansig,
tansig,
tansig,
tansig,
tansig,
tansig,
tansig,
tansig,
tansig,
tansig,
tansig,
tansig,
logsig
logsig
logsig
logsig
logsig
logsig
logsig
logsig
logsig
logsig
logsig
logsig
logsig
logsig
logsig
logsig
logsig
logsig
logsig
*Trial No 15, the architecture of 130-120-120-120-5 gives best convergence, lower computation time and response of training and is good enough
to classify the flank wear at various levels.
5 Neural networks
Cutting tool wear and breakage have a direct influence on
dynamic characteristics of any manufacturing process. Metal
cutting processes are generally non-linear, time dependent, and
vary with material properties and machining conditions. Neural
networks are known to be a mathematical tool to handle such a
dynamic and non linear phenomenon. Most of the researchers
[2, 3, 5, 8] have used feed forward back propagation, self
organizing maps (SOM), probabilistic neural networks (PNN)
using either time domain or frequency domain signals. In past
two decades [18, 19] wavelet transform technique has also
been used in the area of cutting tool condition monitoring
system. A real condition monitoring system is expected to
replace the knowledge and experience of a skilled machine
operator. This can be achieved through proper learning and
training of artificial neural network (ANN) [20]. Neural
Output vectors
0.5 mm
0.4 mm
0.3 mm
0.2 mm
0.0 mm
1
0
0
0
0
0
1
0
0
0
0
0
1
0
0
0
0
0
1
0
0
0
0
0
1
Output
layer
Output layer
Input layer
Hidden layers
Fig. 14 Feed forward neural network with four hidden layer
481
1
1 ex
Output vectors
Ex No 25
Ex No 26
0.5 mm
1.000
0.003
0.001
0.001
0.001
0.4mm
0.000
0.999
0.001
0.000
0.001
0.3 mm
0.000
0.000
0.991
0.003
0.002
0.2 mm
0.002
0.005
0.004
0.991
0.005
0.0 mm
0.011
0.003
0.011
0.013
0.954
0.5 mm
1.000
0.000
0.001
0.002
0.005
0.4 mm
0.001
0.988
0.002
0.002
0.011
0.3 mm
0.003
0.002
0.992
0.000
0.003
0.2 mm
0.015
0.076
0.004
0.929
0.002
0.0 mm
0.037
0.058
0.000
0.024
0.951
482
6 Conclusions
483
Appendix 1
Ex
No
CS
FR
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
500
500
500
500
500
500
500
500
500
350
350
350
350
350
350
350
350
350
200
200
200
200
200
200
200
200
200
500
500
500
300
300
300
100
100
100
500
500
500
300
300
300
100
100
100
500
500
500
300
300
300
100
100
100
5
4
3
5
4
3
5
4
3
5
4
3
5
4
3
5
4
3
5
4
3
5
4
3
5
4
3
0.2330
0.0528
0.0456
0.0759
0.0389
0.0348
0.0492
0.0310
0.0238
0.2750
0.2000
0.0316
0.2530
0.1540
0.0275
0.1890
0.0691
0.0107
0.2650
0.2320
0.1760
0.2410
0.1630
0.1580
0.1060
0.0613
0.0186
0.1580
0.0079
0.0196
0.0298
0.0079
0.0035
0.0033
0.0029
0.0013
0.2330
0.0200
0.0111
0.0456
0.0187
0.0052
0.0348
0.0115
0.0008
0.2650
0.0585
0.0065
0.0621
0.0389
0.0076
0.0613
0.0186
0.0042
0.0298
0.0131
0.0026
0.0132
0.0050
0.0047
0.0019
0.0019
0.0003
0.1050
0.0219
0.0038
0.0247
0.0090
0.0074
0.0105
0.0097
0.0026
0.2320
0.0241
0.0092
0.0261
0.0110
0.0058
0.0145
0.0098
0.0077
0.0091
0.0043
0.0009
0.0113
0.0058
0.0023
0.0028
0.0020
0.0006
0.0199
0.0053
0.0030
0.0128
0.0085
0.0043
0.0066
0.0009
0.0011
0.0345
0.0090
0.0087
0.0442
0.0098
0.0045
0.0129
0.0092
0.0051
0.0107
0.0026
0.0020
0.0070
0.0012
0.0014
0.0061
0.0031
0.0005
0.0111
0.0036
0.0034
0.0083
0.0061
0.0016
0.0064
0.0039
0.0009
0.0153
0.0095
0.0052
0.0132
0.0091
0.0019
0.0112
0.0053
0.0037
Ex
No
CS
FR
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
500
500
500
500
500
500
500
500
500
350
350
350
350
350
350
350
350
350
200
200
200
200
200
200
200
200
200
500
500
500
300
300
300
100
100
100
500
500
500
300
300
300
100
100
100
500
500
500
300
300
300
100
100
100
5
4
3
5
4
3
5
4
3
5
4
3
5
4
3
5
4
3
5
4
3
5
4
3
5
4
3
0.2670
0.2370
0.1570
0.0939
0.0448
0.0239
0.0457
0.0408
0.0191
0.2480
0.2450
0.1640
0.2490
0.1900
0.1430
0.0929
0.0264
0.0249
0.2710
0.2640
0.1690
0.2330
0.1470
0.1310
0.1920
0.1330
0.0601
0.2450
0.0883
0.0277
0.0638
0.0191
0.0087
0.0229
0.0059
0.0065
0.2370
0.0389
0.0110
0.0627
0.0122
0.0057
0.0264
0.0055
0.0045
0.1210
0.0239
0.0017
0.0408
0.0063
0.0039
0.0167
0.0249
0.0044
0.0103
0.0065
0.0035
0.0071
0.0049
0.0024
0.0040
0.0028
0.0015
0.0210
0.0086
0.0054
0.0100
0.0066
0.0033
0.0050
0.0036
0.0031
0.0226
0.0123
0.0085
0.0159
0.0120
0.0062
0.0127
0.0089
0.0081
0.0089
0.0058
0.0025
0.0061
0.0051
0.0017
0.0033
0.0028
0.0007
0.0136
0.0061
0.0033
0.0070
0.0058
0.0021
0.0053
0.0029
0.0007
0.0194
0.0094
0.0037
0.0125
0.0084
0.0045
0.0064
0.0033
0.0010
0.0068
0.0037
0.0017
0.0040
0.0031
0.0025
0.0033
0.0024
0.0019
0.0077
0.0054
0.0044
0.0054
0.0034
0.0027
0.0037
0.0028
0.0025
0.0083
0.0067
0.0051
0.0061
0.0041
0.0034
0.0049
0.0032
0.0028
Ex CS
No
FR
1
2
3
4
5
6
7
8
9
10
11
12
13
500
500
500
300
300
300
100
100
100
500
500
500
300
5
4
3
5
4
3
5
4
3
5
4
3
5
500
500
500
500
500
500
500
500
500
350
350
350
350
7.4488
0.0274
0.0100
0.8566
0.0224
0.0017
0.0500
0.0141
0.0015
13.972
0.5940
0.1176
1.0856
4.2373
0.1118
0.0017
0.0210
0.0031
0.0011
0.3906
0.0079
0.0010
5.7864
0.0141
0.0045
1.8221
0.0141
0.0013
0.0006
0.0025
0.0011
0.0002
0.0007
0.0003
0.0003
0.3940
0.0727
0.0061
0.1274
0.02108
0.00566
0.00229
0.00736
0.00174
0.00053
0.00004
0.00056
0.00009
0.02123
0.01852
0.01562
0.01791
0.001350
0.000378
0.000234
0.001245
0.000166
0.000020
0.000749
0.000148
0.000138
0.269500
0.001401
0.000265
0.013886
484
Table 8 (continued)
Experimental
conditions
Ex
No
14
15
16
17
18
19
20
21
22
23
24
25
26
27
CS
FR
350
350
350
350
350
200
200
200
200
200
200
200
200
200
300
300
100
100
100
500
500
500
300
300
300
100
100
100
Table 10 (continued)
Micro strain for different level of flank wears
0.3 mm
FW
0.0241
0.0159
0.0014
0.0012
0.0007
12.8480
5.6611
0.0168
0.4354
0.0322
0.0199
0.0110
0.0011
0.0009
0.2 mm
FW
0.00196
0.00108
0.00014
0.00064
0.00096
0.65594
0.01325
0.00064
0.02416
0.00437
0.00038
0.00303
0.00080
0.00049
0.0 mm
FW
0.000343
0.000159
0.000803
0.000286
0.000002
0.367030
0.015560
0.006222
0.019056
0.012440
0.004686
0.000729
0.001429
0.000128
Source
DF
SS
Total
Predictor
Constant
Cutting
speed
Feed rate
80
Coef
20.7342
1.939E-03
MS
0.1301015955
SE Coef
0.9838920
2.13193979E04
6.137E-03
3.86197506E04
Depth of 1.296833428 8.32526262Ecut
02
Flank
22.162948554 2.182573027
wear
Source
DF
Cutting
1
speed
Feed rate 1
Depth of 1
cut
Flank
1
wear
T
P
21.07369 0.0
9.099049645 0.0
15.89108878 0.0
15.57708731 0.0
10.15450492 0.0
Coefficient of multiple
determination (R2) =
0.94879
Appendix 2
DF
SS
MS
Regression
0.17390
4.34762E- 166.0451346 0
02
2.61833E04
Residual Error 76
Total
Predictor
Constant
Cutting speed
Feed rate
1.9899E-02
80
Coef
15.23397
2.56E-03
6.37E-03
0.1938043
SE Coef
0.987513
3.218870E-04
5.8018617E04
Depth of cut 1.706460 0.1836045
Flank wear
7.063323 0.63513239
Source
DF
Cutting speed 1
Feed rate
1
Depth of cut 1
Flank wear
1
T
15.4266
7.969620
10.996413
P
0.0
0.0
0.0
9.2942163 0.0
11.121026 0.0
Coefficient of multiple
determination (R2) =
0.8973223476
DF
Regression 4
Residual 76
Error
SS
Source
DF
SS
MS
Regression
Residual Error
Total
Predictor
Constant
Cutting speed
Feed rate
Depth of cut
Flank wear
Source
Cutting speed
Feed rate
Depth of cut
Flank wear
4
76
80
Coef
13.444032
7.05427E-03
9.878094E-03
2.00664334
6.53810364
DF
1
1
1
1
343.3472
80.14645
423.4936
SE Coef
2.185416
9.45E-04
1.88E-03
0.388271
0.934249
85.83681
1.054558
81.3959 0
T
P
6.151702 0.0
7.457052 0.0
5.2537984 0.0
5.1681438 0.0
6.9982416 0.0
Coefficient of multiple
determination (R2) =
0.81075
References
MS
485
14. Cochran WG, Cox GM (1962) Experimental Designs. Wiley, New
York
15. Williams JE, Raja KK (2002) The effects of corner radius and
edge radius on tool flank wear. J manuf process (SME) 4(2):8995
16. Thomas M, Beauchamp Y (2003) Statistical investigation of
modal parameters of cutting tools in dry turning. Int j mach tools
manuf 43(11):10931106
17. Niu YM, Wong YS, Hong GS (1998) An intelligent sensor system
approach for reliable tool flank wear recognition. Int j adv manuf
Technol 14:7784
18. Lee BY, Tarng YS (2004) Application of the discrete wavelet
transform to the monitoring of tool failure in end milling using the
spindle motor. Int j adv manuf technol 15(4):238243
19. Scheffer C, Heyns PS (2001) Wear monitoring in turning
operations using vibration and strain measurements. Mech syst
signal process 15(6):11851202
20. Rangwala S, Dornfeld D (August 1990) Sensor Integration using
neural networks for intelligent tool condition monitoring. J eng
ind 112:219228
21. Ozel T, Nadgir A (2002) Prediction of flank wear by using neural
networks modeling when cutting hardened H-13 steel with
chamfered and honed CBN tools. Int j mach tools manuf
42:287297
22. Zurada JM (1999) Introduction to Artificial Neural Systems, Jaico
Publishing House, New Delhi