Optimum Cutting Condition Determination for Precision Turning

Abstract

One of the biggest problems for precision turning is to find out cutting conditions for the smallest surface roughness and the biggest tool life to satisfy the high accuracy requirement. A new approach for the optimum condition determination has been developed by using multiple sensor machining system. The system sensors mounted on the CNC lathe have measured tool vibrations, cutting forces, motor power and e.m.f. signal. This paper presents the method leading to the determination of the optimal feed value for given cutting conditions. The experimental results indicate that, under gradually changing cutting tool feed, the all turning parameters also alter emphasizing their close correlation. Under this feed variation some of the system measuring parameters have minimum or maximum points that relieve optimum feed determination taking into account all machining conditions. Also, the maximum approach of the tool life has been defined under the optimum feed. The cutting speed increasing leads to increasing optimum feed and its value changes for every pair of cutting tool and machining materials. The results show that the turning under optimum feed would improve surface roughness and tool life at least of 25 percent.