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Tool condition monitoring in the milling process with vegetable based cutting fluids using vibration signatures

  • Thangamuthu Mohanraj , Subramaniam Shankar , Rathanasamy Rajasekar , Ramasamy Deivasigamani and Pallakkattur Muthusamy Arunkumar
Published/Copyright: February 21, 2019
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Abstract

The major difficulty faced in a machining process is predicting the failure of cutting tools and analyzing the stipulated time for tool replacement. The former and latter can be achieved through a monitoring system that surveys the effective condition. This present research work is focused on analyzing tool condition by adopting a vibration signature during the machining of a hybrid aluminum alloy composite using various coolants. The experiments were conducted employing various tools under optimum process parameters utilizing vegetable based cutting oil as a coolant. During the machining process, a vibration signature from the workpiece was acquired using an NI 6221 M series DAQ card allowing for various time domain features to be extracted. The arithmetic mean and skewness significantly increased for dull tools. Based on the extracted features, a decision making algorithm for tool condition monitoring system has been proposed. The result shows that the features extracted increased consecutively with an increase in flank wear.


*Correspondence Address, Prof. Dr. Subramaniam Shankar, Department of Mechatronics Engineering, Kongu Engineering College, Perundurai, Erode, Tamil Nadu 638060, India, E-mail:

Dr. Thangamuthu Mohanraj, born in 1988, is currently working as Assistant Professor in the Department of Mechanical Engineering at the Amrita School of Engineering, Coimbatore, Amrita Vishwa Vidyapeetham, India. He obtained his Ph.D. degree from Anna University, Chennai in 2018. He specializes in mechatronics, sensors and signal processing, sensor fusion, and condition monitoring.

Dr. Subramaniam Shankar, born in 1980, is currently working as Professor in the Department of Mechatronics Engineering at Kongu Engineering College, Erode, Tamil Nadu, India. He received his Ph.D. degree from the Indian Institute of Technology in Madras in 2008. He specializes in computational, mechanics, biomechanics, tribology and condition monitoring.

Dr. Rathanasamy Rajasekar, born in 1982, is currently working as Professor in the Department of Mechanical Engineering at Kongu Engineering College, Erode, Tamil Nadu, India. He received his Ph.D. degree from the Indian Institute of Technology, Kharagpur in 2010. He specializes in materials science, nano materials, manufacturing process, surface coating, and tool condition monitoring.

Dr. Ramasamy Deivasigamani, born in 1949, is currently working as Professor in the Department of Mechanical Engineering at Kongu Engineering College, Erode, Tamil Nadu, India. He obtained his Ph.D degree from Anna University, Chennai, India in 2013 and his M.Tech degree in Foundry from the Indian Institute of Technology, Madras in 1977, and his B.E degree in Metallurgy from the Indian Institute of Science, Bangalore in 1975.

Pallakkattur Muthusamy Arunkumar, born in 1991, is currently working as Assistant Professor in the Department of Mechatronics Engineering at Sri Krishna College of Engineering and Technology, Coimbatore, Tamil Nadu, India. He received his ME degree from Kongu Engineering College, Erode in 2016. He specializes in mechatronics, robotics and automation, and tool condition monitoring.


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Published Online: 2019-02-21
Published in Print: 2019-03-01

© 2019, Carl Hanser Verlag, München

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