Adaptive control of cutting
process using as initial data information signals of
various physical natures, characterizing indirectly
quality of part cutting. The article demonstrates that
among a variety of information signals the cutting
sound is the most informative. Firstly, it is registered
in a contactless manner, making it noise-resistant to
spurious signals generated by operating of a metalcutting
tool, and secondly, the cutting sound
originating at the point of contact of the tool and the
workpiece, has high sensitivity to tool wear and
roughness of the machined surface. Further research
should focus on the development of processing
quality-forecasting methods to promptly change the
cutting modes and therefore prolong the period of the
defect-free part processing

Nahornyi, Volodymyr Viacheslavovych

Polishchuk, R.V.

Zagovora, O.V.

Нагорний, Володимир В`ячеславович

Нагорный, Владимир Вячеславович

Electronic Sumy State University Institutional Repository

   MINISTRY OF EDUCATION AND SCIENCE OF UKRAINE SUMY STATE UNIVERSITY UKRAINIAN FEDERATION OF INFORMATICS         PROCEEDINGS  OF THE V INTERNATIONAL SCIENTIFIC CONFERENCE ADVANCED INFORMATION SYSTEMS AND TECHNOLOGIES  AIST-2017 (Sumy, May 17–19, 2017)        SUMY SUMY STATE UNIVERSITY 2017 The Vth International Conference «Advanced Information Systems and Technologies, AIST 2017» 17-19 May 2017, Sumy, Ukraine 69  Use of sound for adaptive control of the materials cutting process R. V. Polishchuk1, V. V. Nahornyi1, O. V. Zagovora2  1Sumy State University, Sumy, Ukraine, vnagornyi1989@gmail.com 2GESIS Leibniz Institute for the Social Sciences, Cologne, Germany, Olga.Zagovora@gesis.org  Abstract – Adaptive control of cutting process using as initial data information signals of various physical natures, characterizing indirectly quality of part cutting. The article demonstrates that among a variety of information signals the cutting sound is the most informative. Firstly, it is registered in a contactless manner, making it noise-resistant to spurious signals generated by operating of a metal-cutting tool, and secondly, the cutting sound originating at the point of contact of the tool and the workpiece, has high sensitivity to tool wear and roughness of the machined surface. Further research should focus on the development of processing quality-forecasting methods to promptly change the cutting modes and therefore prolong the period of the defect-free part processing. Keywords – tool wear; surface roughness; information signal; sound of cutting. I. INTRODUCTION The quality of product manufacturing must be monitored throughout the entire technological chain, including the process of material cutting operations. Thus, the processing quality is understood as compliance of the workpiece geometry and processed surface roughness with the requirements of technical documentation. The compliance is provided by the adaptive control of the processing system operation. The decisive influence on the quality of controlled parameters is made by the cutting tool wear, which is simultaneously a cause of permanent change in the dynamics of processing equipment. This fact requires implementing of adaptive control with the purpose of varying cutting modes that allow in conditions of ever-changing equipment dynamics to prolong the period of defect-free performance of a predetermined operation of machining materials by cutting. There are two ways of controlling tool wear-direct and indirect. In industrial practice, the indirect way became widespread. In this regard, the adaptive control of tool wear is indirectly evaluated by measuring information signals having various physical nature and accompanying the cutting process.  Effective performance management is dependent upon the noise resistance of the information signal and its sensitivity to the degree of tool wear and the workpiece surface roughness. These properties of the controlled signal are necessary for the effective management of defect-free workpiece manufacturing, because they eliminate the risk of giving erroneous order. The article provides a rationale for the selection of suchlike information signal corresponding to the specified requirements.  II. FORMULATION OF THE PROBLEM The system of adaptive control of the cutting process is based on the measurement of different nature information signals. This signals representing a variety of external factors: mechanical stress, vibration, elastic deformations of the processing system, the electric current, chemical exposure, and the like, which have a decisive influence on the degree of tool wear and, consequently, on the quality of the manufactured product [1]. Therefore, in the process of tool wear such parameters as cutting force [2], the torque [3] and cutting power [4] undergo changes. These parameters are measured by dynamometers. Applying the vibration sensor being disposed, for example, when turning on the tool holder, the tool vibration accompanying inevitably the cutting process is measured [5]  In the course of the wearing tool interaction with a work piece, acoustic emission waves are generated. This signals are recorded by sensors of acoustic emission in the frequency band from 1 kHz to 1 MHz.  Acoustic emission is more sensitive than the force factors and vibration to tool wear [6], but at the same time, it makes acoustic emission more sensitive to noise disturbance caused by the influence of the environment and the work of the structural units of the machine. For this reason, the registration of "integrated settings" is referred to, as they are more resistant to noise disturbance. For example, thermocouples help to monitor the temperature in the cutting zone [7], in the same way thermo – EDS vapors are measured, couples "tool - part ", allowing, according to the authors [8] "to get information about the pace of change in the dynamic behavior of the processing system due to tool wear." The method for measuring the electrical conductivity of the contact "tool - part" enters the group of integral methods [9]. Drawback of "integral" methods lies in their considerable inertia and the need to embed a thermocouple and electrical connections to the instrument. Adaptive control presupposes monitoring tool status as well as surface quality control that is evaluated by the The Vth International Conference «Advanced Information Systems and Technologies, AIST 2017» 17-19 May 2017, Sumy, Ukraine 70  results of the acoustic emission signals measurement and vibration. The vibro-acoustic data signals turn out to be the simplest in the registration and subsequent processing [5]. However, in practice the use of these signals is related to a significant problem that is difficult to solve. These information signals are recorded by contact method. The implementation of the method requires a mechanical communication of the sensor with the source of the information signal (the surface of the object). To meet this requirement, it is necessary to solve two difficult tasks: to choose an informative point on the controlled objects where you want to install the sensor, and to avoid interference, always related to the method of measurement. When monitoring the process of cutting an informative point, is considered, the point of the tool contact with the workpiece. At this point, the useful signal carrying information about the course of the cutting process arises. Placing the sensor at this point is impossible. Selection of other control points, the closest of which, for example, in turning the workpiece is on the cutting tool holder, makes it necessary to exclude the biggest interference from the measurement results Noise disturbance in this case is the vibration generated by the machine constructive operating nodes. To select the useful signal without significant distortion on the background of the intensive level and complex in frequency parasitic vibration is almost impossible. The solution to this problem is achieved by eliminating the sensor contact with the vibrating surface of the machine tool that is implemented with non-contact measurement method. The purpose of this article is grounding the rationale for the selection of a cutting sound as an information signal that is detected in a contactless manner. III. EXPERIMENTAL STUDIES A. Nature of the cutting sound On the surface of the part resulting from machine tool processing irregularities are formed in the form of protrusions and depressions (Fig. 1), called roughness. The cause of the roughness is the trace left by a tool on the machined surface due to mutual oscillation of the tool and the workpiece. This phenomenon that is the tool interaction with the workpiece 135 years ago became the basis of recording, during which the cutter leaves a trail (a phonogram) on the lateral surface of the wax cylinder, and then on the surface of flat records. Fig. 2 Represents a 1000 times magnified part of the sound track records, which is a part of the recorded track on a gramophone record. This soundtrack is just the surface of the part, which is formed while it is processed by a metalworking tool.  Figure 1.  Increased by the microscope surface of the part after processing it by cutting  Figure 2.  Increased by the microscope surface of the record Roughness, similar to a phonogram contains information about the extent of tool wear and the quality of the processed surface of the workpiece, which is inextricably linked with tool wear. A cutting sound is recorded by microphone typically of electret type (Fig. 3). The voltage of the electrical signal at the output of the microphone varies according to a change in the recorded sound.  Figure 3.  Installation example of microphone approximately  the cutting area Results of the studies revealed that the cutting sound has the properties of noise resistance, consequently it can The Vth International Conference «Advanced Information Systems and Technologies, AIST 2017» 17-19 May 2017, Sumy, Ukraine 71  be considered as the initial information signal used in the adaptive control process of cutting. In particular, for this purpose the measured signal  is reduced to the dimensionless form , where ,  – is an value of the sound, defined respectively in the current time and in the beginning of cutting process.  At the same time, the cutting sound should ensure solving the basic problem of adaptive control - maintaining the required in the part manufacturing documents quality, characterizing the degree of compliance of the part geometry and the purity of its surface with the drawing requirements. Geometric accuracy is determined by the tool wear and surface finish by the size of its roughness. The degree of correlation between the sound and these parameters has been studied experimentally. B. The ratio between the tool wear and cutting sound The reason for deviation of the part geometry from the details of the drawing is sized tool wear of the cutting tool hr , equal in magnitude and opposite in sign of radius change Rд of the processed workpiece surface (fig. 4). The purpose of the experiments was to determine the correlation between the sound and tool wear while workpiece being machined on a lathe.   Figure 4.  The deterioration of the geometric accuracy of the part because of the size wear of the tool blade In the course of the experiments, the sound signal, was measured continuously. Measurements were carried out via a microphone installed near the cutting zone (Fig. 6) with the transmission of signal to the computer. Simultaneously, in steps (in two tool passes) using a measuring digital microscope, we recorded value of chamfer wear of major back surface VB, мм of the tool. The experiment was stopped, when the maximum allowable value of wear was reached. The experimental results are shown in fig. 5, there is a graph of cutting sound change (parameter trendSЕ ) and the curve of wear VB, as well as information about the correlation dependence between them, characterized by the correlation coefficient value R, equal to 0.926.  a)  б) Figure 5.  The relation between the curve of the tool wear and sound trend accompanying the treating by the cutting insert P25 of steel 12X18H10T for modes: S = 33 m/min, f = 0,15 mm/rev,  a = 1,0 mm; a) the curve of wear VB and the trend of sound SЕ ; b) the regression relationship between the dimensionless quantity of soundSЕ  and wear VB As we see, the correlation of cutting sound and tool wear is big enough, that objectively indicates a high degree of coordination of change in the sound trend and wear curve. C. The relationship between treated surface roughness and a cutting sound The aim of the experiment was to determine the correlation dependence between the dimensionless sound parameter of  (1) and high-altitude Rа parameter characterizing the roughness. The roughness was measured at the longitudinal turning of steel billet St.40h on modes given in the caption to fig. 5. The roughness parameter Ra measurements were carried out periodically every five passes using a cutter-type profiler 283. The results of the measurements were recorded by the instrument dial indicator and additionally recorded on a laptop (fig. 6). The signal recorded on a laptop, subjected to further processing to determine the correlation between sound trends and roughness parameter. The Vth International Conference «Advanced Information Systems and Technologies, AIST 2017» 17-19 May 2017, Sumy, Ukraine 72   Figure 6.  Registration roughness parameter Ra through profilometer type 283 and a laptop The experimental results, are shown in fig. 7. In addition, for clarity and ease of comparison the roughness and sound roughness Ra , as well as the sound parameter , is given to the dimensionless form ,)()(0RaRaaRaR where )(),( 0  RaRa is an altitude roughness parameter defined respectively in the cutting process beginning and in the current time.Experiments have established that the correlation coefficient R between the sound trends and roughness parameter Ra equals to 0.944 (fig. 7).  Figure 7.  Comparison of sound trends (parameter SЕ ) and roughness ( aR ) CONCLUSIONS Thus, the results of studies presented in the article indicate the feasibility of using for the adaptive control of machining materials sound signal as initial information that is based on the following experimentally proven provisions:  in contrast to the data signals, measured via contact method and subject, therefore, to noise disturbance generated by mechanical vibrations of the machine, a non-contact method of sound measurements via a microphone placed near the cutting area, and the transition in the processing of the measurement results to the dimensionless quantity of sound , provides noise resistant;  sound trend and tool wear curve change during the cutting process with a high degree of coordination, as proven by a significant  quantity of their mutual correlation coefficient R = 0,926;  sound trends and altitude roughness parameter Ra, characterized by a correlation coefficient R, equal to 0.944. Further research on the improvement of adaptive control of the cutting process should be directed at the development of quality forecasting methods of processing, allowing in the process of adaptive control to quickly determine the moment of the timely replacement of extremely worn-out tool. To solve this problem it is necessary throughout the entire workpiece treatment period monitor the cutting sound trend, quickly analyzing the nature of change and varies according to the analyses results cutting modes in order to extend the period of defect-free performance of a given technological operation.  ACKNOWLEDGMENT The work was performed as part of the state budget scientific research theme of the Sumy State University, "Models and information design and management technologies in complex systems" (state registration number 0115U001569).  REFERENCES: [1] Solomentsev Y. M. (et al.): The adaptive control of the technological process, 536 pp., Mechanical Engineering, Moscow (1980) (in Russian) [2]  Oraby S. E. Development of Models for Tool Wear Force Relationship in Metal Cutting / S. E. Oraby, D. R. Hayhurst // Int. J. Mach. Tools Manuf. – 1991. – № 33. – P. 125–138. [3]  Shao H. A cutting power model for tool wear monitoring in milling / H. Shao, H. L. Wang, X. M. Zhao // International Journal of Machine Tools & Manufacture, 2004. – February 2004. – № 44. – P. 105–108. [4]  Bolotin Yu. Z. Diagnosis life of the cutting tool / Yu. Z. Bolotin, V. Granovsky // Mashinostroitel. – 1989. – № 11. – P. 30. (in Russian) [5] Litao Wang. Tool wear monitoring in reconfigurable machining systems through Wavelet analysis / Wang Litao, G. Mostafa Mehrabi  Kannatey-Asibu Jr. Elijah // Engineering Research Center for Reconfigurable Machining Systems University of Michigan. – Ann Arbor, MI 48109–2125. [6] Moriwaki T. A New Approach to Automatic Detection of Life of Coated Tool Based on Acoustic Emission Measurement / Т. Moriwaki, М. Tobito // ASME J. Eng. Ind. – 1990. – № 112. –  P. 212–218. [7]  Kretinin O.V. On the question of obtaining rapid assessment tool wear parameters of the fast / O.V. Kretinin, Klepin A.P., A.R. Quarters [et al.] // The theory of friction, lubrication and machinability of metals: works GPI.- Gorky, 1977. - Vol. № 4. -  P. 112-121. (in Russian) [8] Kretinin O.V. A possible approach to the assessment of contact phenomena at boundary lubrication / O.V. Kretinin, S.A. Kudryavtsev // Automated technology and mechatronic systems in mechanical engineering: Proc. scientific. works. - Ufa: USATU, 1997. – P. 152-159. (in Russian) [9]  Kourov GN Identification cutting temperature in the ACS process of turning on a lathe / G.N. Kourov, Yu. M. Kichko, I.I. Zubarev // Coll. scientific. works: Intelligent mechatronic machine systems.– Ufa, 2003. – 120 p. (in Russian)   

Use of sound for adaptive control of the materials cutting process

SocioEconomic Challenges Journal (Sumy State University)

  
 
MINISTRY OF EDUCATION AND SCIENCE OF UKRAINE 
SUMY STATE UNIVERSITY 
UKRAINIAN FEDERATION OF INFORMATICS 
 
 
 
 
 
 
 
 
PROCEEDINGS  
OF THE V INTERNATIONAL SCIENTIFIC 
CONFERENCE 
ADVANCED INFORMATION 
SYSTEMS AND TECHNOLOGIES 
 
AIST-2017 
(Sumy, May 17–19, 2017) 
 
 
 
 
 
 
 
SUMY 
SUMY STATE UNIVERSITY 
2017 
The Vth International Conference «Advanced Information Systems and Technologies, AIST 2017» 
17-19 May 2017, Sumy, Ukraine 
69 
 
Use of sound for adaptive control 
of the materials cutting process 
R. V. Polishchuk
1
, V. V. Nahornyi
1
, O. V. Zagovora
2 
 1
Sumy State University, Sumy, Ukraine, vnagornyi1989@gmail.com 
2
GESIS Leibniz Institute for the Social Sciences, Cologne, Germany, Olga.Zagovora@gesis.org 
 
Abstract – Adaptive control of cutting 
process using as initial data information signals of 
various physical natures, characterizing indirectly 
quality of part cutting. The article demonstrates that 
among a variety of information signals the cutting 
sound is the most informative. Firstly, it is registered 
in a contactless manner, making it noise-resistant to 
spurious signals generated by operating of a metal-
cutting tool, and secondly, the cutting sound 
originating at the point of contact of the tool and the 
workpiece, has high sensitivity to tool wear and 
roughness of the machined surface. Further research 
should focus on the development of processing 
quality-forecasting methods to promptly change the 
cutting modes and therefore prolong the period of the 
defect-free part processing. 
Keywords – tool wear; surface roughness; 
information signal; sound of cutting. 
I. INTRODUCTION 
The quality of product manufacturing must be 
monitored throughout the entire technological chain, 
including the process of material cutting operations. 
Thus, the processing quality is understood as compliance 
of the workpiece geometry and processed surface 
roughness with the requirements of technical 
documentation. The compliance is provided by the 
adaptive control of the processing system operation. 
The decisive influence on the quality of controlled 
parameters is made by the cutting tool wear, which is 
simultaneously a cause of permanent change in the 
dynamics of processing equipment. This fact requires 
implementing of adaptive control with the purpose of 
varying cutting modes that allow in conditions of ever-
changing equipment dynamics to prolong the period of 
defect-free performance of a predetermined operation of 
machining materials by cutting. 
There are two ways of controlling tool wear-direct 
and indirect. In industrial practice, the indirect way 
became widespread. In this regard, the adaptive control of 
tool wear is indirectly evaluated by measuring 
information signals having various physical nature and 
accompanying the cutting process.  
Effective performance management is dependent 
upon the noise resistance of the information signal and its 
sensitivity to the degree of tool wear and the workpiece 
surface roughness. These properties of the controlled 
signal are necessary for the effective management of 
defect-free workpiece manufacturing, because they 
eliminate the risk of giving erroneous order. 
The article provides a rationale for the selection of 
suchlike information signal corresponding to the 
specified requirements.  
II. FORMULATION OF THE PROBLEM 
The system of adaptive control of the cutting process 
is based on the measurement of different nature 
information signals. This signals representing a variety of 
external factors: mechanical stress, vibration, elastic 
deformations of the processing system, the electric 
current, chemical exposure, and the like, which have a 
decisive influence on the degree of tool wear and, 
consequently, on the quality of the manufactured product 
[1]. 
Therefore, in the process of tool wear such parameters 
as cutting force [2], the torque [3] and cutting power [4] 
undergo changes. These parameters are measured by 
dynamometers. Applying the vibration sensor being 
disposed, for example, when turning on the tool holder, 
the tool vibration accompanying inevitably the cutting 
process is measured [5]  
In the course of the wearing tool interaction with a 
work piece, acoustic emission waves are generated. This 
signals are recorded by sensors of acoustic emission in 
the frequency band from 1 kHz to 1 MHz.  Acoustic 
emission is more sensitive than the force factors and 
vibration to tool wear [6], but at the same time, it makes 
acoustic emission more sensitive to noise disturbance 
caused by the influence of the environment and the work 
of the structural units of the machine. 
For this reason, the registration of "integrated 
settings" is referred to, as they are more resistant to noise 
disturbance. For example, thermocouples help to monitor 
the temperature in the cutting zone [7], in the same way 
thermo – EDS vapors are measured, couples "tool - part 
", allowing, according to the authors [8] "to get 
information about the pace of change in the dynamic 
behavior of the processing system due to tool wear." The 
method for measuring the electrical conductivity of the 
contact "tool - part" enters the group of integral methods 
[9]. Drawback of "integral" methods lies in their 
considerable inertia and the need to embed a 
thermocouple and electrical connections to the 
instrument. 
Adaptive control presupposes monitoring tool status 
as well as surface quality control that is evaluated by the 
The Vth International Conference «Advanced Information Systems and Technologies, AIST 2017» 
17-19 May 2017, Sumy, Ukraine 
70 
 
results of the acoustic emission signals measurement and 
vibration. 
The vibro-acoustic data signals turn out to be the 
simplest in the registration and subsequent processing [5]. 
However, in practice the use of these signals is related to 
a significant problem that is difficult to solve. These 
information signals are recorded by contact method. The 
implementation of the method requires a mechanical 
communication of the sensor with the source of the 
information signal (the surface of the object). To meet 
this requirement, it is necessary to solve two difficult 
tasks: to choose an informative point on the controlled 
objects where you want to install the sensor, and to avoid 
interference, always related to the method of 
measurement. 
When monitoring the process of cutting an 
informative point, is considered, the point of the tool 
contact with the workpiece. At this point, the useful 
signal carrying information about the course of the 
cutting process arises. Placing the sensor at this point is 
impossible. Selection of other control points, the closest 
of which, for example, in turning the workpiece is on the 
cutting tool holder, makes it necessary to exclude the 
biggest interference from the measurement results 
Noise disturbance in this case is the vibration 
generated by the machine constructive operating nodes. 
To select the useful signal without significant distortion 
on the background of the intensive level and complex in 
frequency parasitic vibration is almost impossible. The 
solution to this problem is achieved by eliminating the 
sensor contact with the vibrating surface of the machine 
tool that is implemented with non-contact measurement 
method. 
The purpose of this article is grounding the rationale for 
the selection of a cutting sound as an information signal 
that is detected in a contactless manner. 
III. EXPERIMENTAL STUDIES 
A. Nature of the cutting sound 
On the surface of the part resulting from machine tool 
processing irregularities are formed in the form of 
protrusions and depressions (Fig. 1), called roughness. 
The cause of the roughness is the trace left by a tool on 
the machined surface due to mutual oscillation of the tool 
and the workpiece. This phenomenon that is the tool 
interaction with the workpiece 135 years ago became the 
basis of recording, during which the cutter leaves a trail 
(a phonogram) on the lateral surface of the wax cylinder, 
and then on the surface of flat records. 
Fig. 2 Represents a 1000 times magnified part of the 
sound track records, which is a part of the recorded track 
on a gramophone record. This soundtrack is just the 
surface of the part, which is formed while it is processed 
by a metalworking tool. 
 
Figure 1.  Increased by the microscope surface of the part after 
processing it by cutting 
 
Figure 2.  Increased by the microscope surface of the record 
Roughness, similar to a phonogram contains 
information about the extent of tool wear and the quality 
of the processed surface of the workpiece, which is 
inextricably linked with tool wear. 
A cutting sound is recorded by microphone typically 
of electret type (Fig. 3). The voltage of the electrical 
signal at the output of the microphone varies according to 
a change in the recorded sound. 
 
Figure 3.  Installation example of microphone approximately  
the cutting area 
Results of the studies revealed that the cutting sound 
has the properties of noise resistance, consequently it can 
The Vth International Conference «Advanced Information Systems and Technologies, AIST 2017» 
17-19 May 2017, Sumy, Ukraine 
71 
 
be considered as the initial information signal used in the 
adaptive control process of cutting. In particular, for this 
purpose the measured signal  is reduced to the 
dimensionless form , where , 
 – is an value of the sound, defined respectively 
in the current time and in the beginning of cutting 
process.  
At the same time, the cutting sound should ensure 
solving the basic problem of adaptive control - 
maintaining the required in the part manufacturing 
documents quality, characterizing the degree of 
compliance of the part geometry and the purity of its 
surface with the drawing requirements. Geometric 
accuracy is determined by the tool wear and surface 
finish by the size of its roughness. The degree of 
correlation between the sound and these parameters has 
been studied experimentally. 
B. The ratio between the tool wear and cutting sound 
The reason for deviation of the part geometry from 
the details of the drawing is sized tool wear of the cutting 
tool hr , equal in magnitude and opposite in sign of radius 
change Rд of the processed workpiece surface (fig. 4). 
The purpose of the experiments was to determine the 
correlation between the sound and tool wear while 
workpiece being machined on a lathe. 
 
 
Figure 4.  The deterioration of the geometric accuracy of the part 
because of the size wear of the tool blade 
In the course of the experiments, the sound signal, 
was measured continuously. Measurements were carried 
out via a microphone installed near the cutting zone (Fig. 
6) with the transmission of signal to the computer. 
Simultaneously, in steps (in two tool passes) using a 
measuring digital microscope, we recorded value of 
chamfer wear of major back surface VB, мм of the tool. 
The experiment was stopped, when the maximum 
allowable value of wear was reached. 
The experimental results are shown in fig. 5, there is a 
graph of cutting sound change (parameter trend
SЕ ) and 
the curve of wear VB, as well as information about the 
correlation dependence between them, characterized by 
the correlation coefficient value R, equal to 0.926. 
 
a) 
 
б) 
Figure 5.  The relation between the curve of the tool wear and 
sound trend accompanying the treating by the cutting insert P25 of 
steel 12X18H10T for modes: S = 33 m/min, f = 0,15 mm/rev, 
 a = 1,0 mm; a) the curve of wear VB and the trend of sound 
SЕ ; 
b) the regression relationship between the dimensionless quantity of 
sound
SЕ  and wear VB 
As we see, the correlation of cutting sound and tool 
wear is big enough, that objectively indicates a high 
degree of coordination of change in the sound trend and 
wear curve. 
C. The relationship between treated surface roughness 
and a cutting sound 
The aim of the experiment was to determine the 
correlation dependence between the dimensionless sound 
parameter of  (1) and high-altitude Rа parameter 
characterizing the roughness. The roughness was 
measured at the longitudinal turning of steel billet St.40h 
on modes given in the caption to fig. 5. The roughness 
parameter Ra measurements were carried out periodically 
every five passes using a cutter-type profiler 283. The 
results of the measurements were recorded by the 
instrument dial indicator and additionally recorded on a 
laptop (fig. 6). The signal recorded on a laptop, subjected 
to further processing to determine the correlation between 
sound trends and roughness parameter. 
The Vth International Conference «Advanced Information Systems and Technologies, AIST 2017» 
17-19 May 2017, Sumy, Ukraine 
72 
 
 
Figure 6.  Registration roughness parameter Ra through 
profilometer type 283 and a laptop 
The experimental results, are shown in fig. 7. In 
addition, for clarity and ease of comparison the roughness 
and sound roughness Ra , as well as the sound 
parameter , is given to the dimensionless form 
,
)(
)(
0









Ra
Ra
aRaR where )(),( 0  RaRa is an 
altitude roughness parameter defined respectively in the 
cutting process beginning and in the current 
time.Experiments have established that the correlation 
coefficient R between the sound trends and roughness 
parameter Ra equals to 0.944 (fig. 7). 
 
Figure 7.  Comparison of sound trends (parameter 
SЕ ) and 
roughness ( aR ) 
CONCLUSIONS 
Thus, the results of studies presented in the article 
indicate the feasibility of using for the adaptive control of 
machining materials sound signal as initial information 
that is based on the following experimentally proven 
provisions: 
 in contrast to the data signals, measured via contact 
method and subject, therefore, to noise disturbance 
generated by mechanical vibrations of the machine, a 
non-contact method of sound measurements via a 
microphone placed near the cutting area, and the 
transition in the processing of the measurement results to 
the dimensionless quantity of sound , provides noise 
resistant; 
 sound trend and tool wear curve change during the 
cutting process with a high degree of coordination, as 
proven by a significant  quantity of their mutual 
correlation coefficient R = 0,926; 
 sound trends and altitude roughness parameter Ra, 
characterized by a correlation coefficient R, equal to 
0.944. 
Further research on the improvement of adaptive 
control of the cutting process should be directed at the 
development of quality forecasting methods of 
processing, allowing in the process of adaptive control to 
quickly determine the moment of the timely replacement 
of extremely worn-out tool. To solve this problem it is 
necessary throughout the entire workpiece treatment 
period monitor the cutting sound trend, quickly analyzing 
the nature of change and varies according to the analyses 
results cutting modes in order to extend the period of 
defect-free performance of a given technological 
operation.  
ACKNOWLEDGMENT 
The work was performed as part of the state budget 
scientific research theme of the Sumy State University, 
"Models and information design and management 
technologies in complex systems" (state registration 
number 0115U001569).  
REFERENCES: 
[1] Solomentsev Y. M. (et al.): The adaptive control of the 
technological process, 536 pp., Mechanical Engineering, Moscow 
(1980) (in Russian) 
[2]  Oraby S. E. Development of Models for Tool Wear Force 
Relationship in Metal Cutting / S. E. Oraby, D. R. Hayhurst // Int. J. 
Mach. Tools Manuf. – 1991. – № 33. – P. 125–138. 
[3]  Shao H. A cutting power model for tool wear monitoring in milling 
/ H. Shao, H. L. Wang, X. M. Zhao // International Journal of 
Machine Tools & Manufacture, 2004. – February 2004. – № 44. – 
P. 105–108. 
[4]  Bolotin Yu. Z. Diagnosis life of the cutting tool / Yu. Z. Bolotin, V. 
Granovsky // Mashinostroitel. – 1989. – № 11. – P. 30. (in Russian) 
[5] Litao Wang. Tool wear monitoring in reconfigurable machining 
systems through Wavelet analysis / Wang Litao, G. Mostafa 
Mehrabi  Kannatey-Asibu Jr. Elijah // Engineering Research Center 
for Reconfigurable Machining Systems University of Michigan. – 
Ann Arbor, MI 48109–2125. 
[6] Moriwaki T. A New Approach to Automatic Detection of Life of 
Coated Tool Based on Acoustic Emission Measurement / Т. 
Moriwaki, М. Tobito // ASME J. Eng. Ind. – 1990. – № 112. –  
P. 212–218. 
[7]  Kretinin O.V. On the question of obtaining rapid assessment tool 
wear parameters of the fast / O.V. Kretinin, Klepin A.P., A.R. 
Quarters [et al.] // The theory of friction, lubrication and 
machinability of metals: works GPI.- Gorky, 1977. - Vol. № 4. -  
P. 112-121. (in Russian) 
[8] Kretinin O.V. A possible approach to the assessment of contact 
phenomena at boundary lubrication / O.V. Kretinin, S.A. 
Kudryavtsev // Automated technology and mechatronic systems in 
mechanical engineering: Proc. scientific. works. - Ufa: USATU, 
1997. – P. 152-159. (in Russian) 
[9]  Kourov GN Identification cutting temperature in the ACS process 
of turning on a lathe / G.N. Kourov, Yu. M. Kichko, I.I. Zubarev // 
Coll. scientific. works: Intelligent mechatronic machine systems.– 
Ufa, 2003. – 120 p. (in Russian) 
 
 


https://essuir.sumdu.edu.ua/bitstream/123456789/55758/1/Polishchuk_Tool.pdf

Use of sound for adaptive control of the materials cutting process

Abstract

Similar works

Full text

Available Versions

Electronic Sumy State University Institutional Repository

SocioEconomic Challenges Journal (Sumy State University)