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Real-time monitoring of flank wear behavior of ceramic cutting tool in turning hardened steels

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Abstract

Flank wear of an alumina-based ceramic cutting tool was determined in hard turning two workpieces (AISI 4340 and 52100 hardened steels) at three cutting speeds (142, 181, and 264 m/min) to devise a real-time monitoring system. Results of the six turning tests were assessed using Kruskal–Wallis test, regression models, and linear trend analysis. Multiple non-linear regression models that explained variation in flank wear as a function of time (second) had a range of \( R_{\rm{adj}}^2 \) values of 27.7% for the test 4340-142 to 95% for the test 52100-181. Linear trend models revealed that the highest flank wear rate of the ceramic cutting tool belonged to the test 52100-181. Interaction effect of the three cutting speeds and the two workpiece types was determined to account for 82.2% of variation in flank wear (P < 0.001). The real-time monitoring system designed in this study appeared to be promising in terms of determining and quantifying flank wear behavior of the ceramic cutting tool and optimal hard turning conditions.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Faculty of Engineering and Architecture, Abant Izzet Baysal University, 14280, Bolu, Turkey

    Ahmet Cakan

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  1. Ahmet Cakan
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Correspondence to Ahmet Cakan.

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Cakan, A. Real-time monitoring of flank wear behavior of ceramic cutting tool in turning hardened steels. Int J Adv Manuf Technol 52, 897–903 (2011). https://doi.org/10.1007/s00170-010-2793-1

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  • DOI: https://doi.org/10.1007/s00170-010-2793-1

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