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Manuf. and Ind. Eng., 11(2), 2012, ISSN 1338-6549

Faculty of Manuf. Tech. TUKE

Influence of Tool Wear and Chip Forming Mechanism
on Tool Vibrations

Aco Anti, Jozef N. Marcincin, Nikolae Ungureanu, Mijodrag Miloevi,
Dusan Kovacevi


Abstract
During machining process, vibrations on tool carrier were measured in the vicinity of cutting zone. Analysis of
generated chip and vibration signals during machining confirms hypothesis that changes in tool wear degree directly
impacts chip form and type of segmentation. Direct microscopic analysis of chip was used to determine a correlation
between tool wear degree and morphology of chip cross section. This investigation contributes to a better understanding of
chip forming mechanism and type of segmentation, allowing us to collect quality input information which could be used for
subsequent development of a system for tool wear identification. In this paper is presented an experimental investigation of
the influence of tool wear on chip forming mechanism and type of segmentation in turning.
Keywords: tool wear, chip forming, tool vibrations


1 Introduction
Timely detection and replacement of worn tools is one
of the key research areas in the domain of optimization of
cost-effectiveness and productivity in modern automated
manufacturing. It is estimated that an accurate and reliable
system for tool wear monitoring and identification can
contribute to increase of cutting speed by 10-50%. The
reduction of manufacturing downtime by timely tool
replacement contributes to reduction of total manufacturing
costs by 10% to 40% [1]. Investigations related to increase
of reliability and performance of systems for tool wear
monitoring are directed towards experimental determination
of chip forming mechanism and its influence on the
machine tooltoolworkpiece system, as well as the FEM
simulation of cutting process [2], [3]. Chip forming
mechanism and chip morphology are characteristics which
provide key information on the machining process and
machined surface quality. Chip forming mechanism and
type of chip segmentation exert primary influence on tool
life and machined surface quality. Proper identification and
understanding of chip forming mechanism can help us
detect tool wear in machining of harder materials and
special steels. Chip forming mechanism, as well as its form
and flow over tool rake surface, significantly impact the tool
wear and machined surface quality. Recent investigations
emphasize the importance of parametric analysis of mutual
influence between the tool wear degree and chip forming
mechanism [4], [5].
The analysis of tool wear parameters has established that
the most important ones are: crater wear on rake face, flank
wear, and cutting edge wear. The chip formed in conditions
of intensified cutting speeds causes increased pressure and
friction on the tool rake surface, while within the tool/chip
interface it directly promotes tool wear, i.e., crater wear.
Dutta [6], investigated the influence of cutting parameters
on various types of composites used in tool materials, and
how they affect the quality of machined surface and tool

wear mechanism during machining. Among other parame-
ters, he analyzed the macroscopic and microscopic chip
structure formed under the influence of various machining
regimes. Ozcatalbas [7], analyzed the macroscopic and
microscopic chip form depending on the cutting regime,
also taking into consideration the tool wear degree, as a
secondary parameter. He analyzed the influence of cutting
speed on the chip cutting ratio, as well as the change of tool
wedge geometry due to cutting edge build-up.
Generation of segmented chip during machining causes
impulse forces which, in turn, generate tool vibrations.
Investigations related to registration of dynamic parameters
of lamellae forming during machining encompass acquisi-
tion and processing of various sensor signals. Anti
13
used
power spectral density (PSD) sensors and a dynamometer to
monitor various dynamic parameters during machining.
Obtained results were used as prerequisites for the develop-
ment of artificial neural network (ANN) for tool wear
monitoring. During machining, chip lamellae slip along a
narrow zone of thermal softening, generating pronounced
chip segments. The generated chip features excessive roug-
hness on the free surface, which indicates the presence of
adiabatic shear in chip generation. Bery and Gerald [8],
considered the chip forming mechanisms in the machining
of tempering steels, concluding that saw-tooth chip is
generated due to thermal softening and adiabatic shear in
the narrow zone.
The goal of this investigation is to determine the
dependence between the type of generated chip and tool
wear degree during turning. Direct microscopic measure-
ments were performed to analyze chip cross section. In
addition, during experiment, characteristic chip parameters
were analyzed to establish the correlation with tool wear,
i.e., tool wedge degradation.


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2 Experimental setup
Machining experiments were performed on CNC GU
600 lathe manufactured by INDEX and installed in a
laboratory of the Faculty of Technical Sciences in Novi Sad.
Investigation of tool wear process encompassed the moni-
toring of the dominant wear mechanism through following
parameters: wear band, crater wear and tool life. In the cou-
rse of the turning process, vibration signal and cutting force
were registered at the tool shank. For each tool pass the
generated chip segments were sampled. The setup of tool
sensors, as well as the dimension of workpiece used in this
experiment are shown in Fig. 1. During the experiment two
cutting speeds were employed, 200 to 250m/min, in conjun-
ction with 0.15 and 0.3mm/o feed rates. Cross section of the
tool shank used in the experiment was 20x20mm. The ma-
chining was performed with P25 tool inserts designated
TNMM 110408. The vibration and force signals were sam-
pled at 625kHz, with A/D converter NI625 USB "National
Instruments". Workpiece material, 42CrMo4, was of gua-
ranteed mechanical and chemical properties, with 290HB
hardness.

Figure 1 Experimental setup
3 Experimental results
Experimental results were obtained through a
combination of direct measurements of chip characteristic
dimensions on an electronic microscope, and indirect sensor
measurements of forces and vibrations. Variations in tool
wear degree were monitored through measurement of wear
band width (VB) which defines the tool flank wear. This
measurement was performed periodically on a tool micro-
scope.
3.1 Forming of continuous chip
Continuous chip form is generated through material
shear in the primary cutting zone without clearly observable
segment borders in the cross section, and without distinctive
segment tips on the free chip surface. The height of seg-
ments on the free chip surface is very small and corresponds
to the width of a single segment. The upper chip zone,
closer to the free surface, is mildly wrinkled with only slight
indication of incipient lamellae, as shown in Fig. 2 (a).
Investigations have shown that that chip form is largely
influenced by changes in tool wedge geometry which pro-
gress during machining process. Fig. 2 (a) shows cross
section of continuous chip generated by a fresh tool insert.
Obviously, continuous segmentation is taking place, without
distinctive separation between chip segments.

a)

b)
Figure 2 Tool wear in relation to chip generation,
a) continuous chip, b) saw-tooth
As the wear band and wear crater on tool rake surface
progressively grow, i.e., the cutting geometry degrades, Fig.
2 (b), the chip form also changes. It is evident that the
formed segments were generated through a cyclical process
(from the first to the last segment). After a certain machi-
ning time, due to the change in tool wear degree, i.e.,
cutting geometry, the chip form begins its transformation.
Tool side of the chip becomes wrinkled and uneven when
compared to that generated by fresh tool insert.
Rather than creating initial crack and spreading the
break towards tool side of the chip through the primary
cutting zone, chip segmentation occurs due to material
deformation in the narrow band through thermal softening
and adiabatic shear mechanisms. The change of chip form
reflects on the vibration signal, machined surface quality,
and, consequently, the total cost of machining energy.
4 Frequency of tool vibration
Cutting tool vibrations during machining occur due to
friction on rake and flank tool surfaces, chip segmentation,
roughness of machined surface, etc. The increase of cutting
speed leads to gradual decrease of continuous shear and the
chip becomes segmented in a periodical manner showing
very pronounced shear zones due to higher temperatures. In
the shear zone, material deformation is pronounced, while
being much lower in the very segment, which can be seen in
Fig. 3. The degree of chip deformation during cutting
process can be calculated from [9]:
=(h
1
-h
2
)/ h
2
(1)
This degree of chip deformation was calculated for the
five contiguous chip segments and mean value was used as
relevant parameter. Shown in Fig. 3(a) are parameters
which were measured and used to calculate the degree of
chip deformation. Based on measured parameters shown in
Fig. 3(a), and calculated degrees of chip segmentation, a
diagram was made which shows the correlation between
tool wear degree and chip segmentation degree, shown in
Fig. 3(b).

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Figure 3 a) Parameters for calculation of chip
deformation degree, b) Dependence of chip segmentation
degree on tool wear
The measurements showed that during the initial phase
(fresh tool insert), for all cutting regimes, a continuous chip
is generated. Once a particular tool wear degree is reached,
the chip changes its forming mechanism which results in a
saw-tooth chip form. This change in cross section geometry
and form is gradual and without abrupt transitions from one
form to another. Certain variations in chip deformation
degree, observed during experiment, can be attributed to
build-ups on cutting edge, i.e., the change of cutting geo-
metry during the cutting process.
5 Character of vibrations during chip
forming process
The forming of single chip segments during generation
of discontinuous chip, results in increased energy release
and higher vibration amplitudes in comparison with conti-
nuous chip. In addition, the consequence of discontinuous
chip forming is higher deformation energy, adiabatic shear,
varied vibration response, and occurrence of self-excited
vibrations. Tool self-excited vibrations are within the 1kHz
- 50kHz range, thus some resonance can be attributed to
chip segmentation. The forming of segmented chip can be
viewed as the process of discrete excitation of machining
system by a series of impulses whose frequency can be
determined within acceptable error margin. The monitoring
of signal, i.e., frequency of chip segment forming, revealed
changes in high-frequency part of the spectrum. This was
visible as the amplification of the generated signal, as
shown in Fig. 4. The frequency of lamellae generation is
destabilized by the primary shear zone and chip forming
mechanism. The difference in signal intensities is related to
release of higher energy during forming of discontinued
chip, as well as higher friction at chip/tool interface. Fig. 4
illustrates the described occurrences speaking in favour of
the assumption that vibration range above 1kHz contains the
signal which can be used for tool wear identification. The
spectrum of vibrations measured on tool shank close to the
cutting zone, is a good indicator of the change in chip foring
mechanism and chip type, caused by tool wear progression,
i.e., cutting edge degradation.

Figure 4 Energy distribution along frequency axis
depending on tool wear degree
Figure 5 illustrates the spectra of signal (in [dB]) for va-
rious tool wear degrees, with following parameters: window
=2048; noverlap=512; pwelch (data_N(:,1), window, nover-
lap,[], Fs). Frequency spectrum was limited to 50 kHz.
Beside cutting regimes, and state and characteristics of
workpiece material, it is tool wear degree that also exerts
great influence on the type of chip generated during machi-
ning. Progression of tool wear leads to the change of chip
type and form regardless of constant machining parameters:
speed, feed rate, depth of cut, and material characteristics.
Changes in chip type are caused by variable cutting geo-
metry which is the function of tool wear degree. Changes in
cutting geometry and chip type directly influence the
considered parameters within the analysed high-frequency
part of vibration spectrum.

Figure 5 Variations in vibration signal spectrum along the
frequency axis, depending on tool wear degree


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6 Conclusions
Through widening of wear band and tool crater wear,
the chip changes form, becomes rougher, wrinkled and
chipped at the ends, while the type of chip segmentation
changes into discontinuous with highly pronounced teeth on
the free chip surface. The cross section of generated chip
exhibits very pronounced wrinkles on the free side in the
various zones of material deformation during machining.
This indicates the combined action of stress strengthening
and thermal softening, i.e., the existence of dual action in
chip formation. The zone of thermo-plastic instability has a
dominant role up until the emergence of the shear zone and
forming of chip segments, when the cutting process con-
forms to adiabatic shear theory. The change in chip type
causes the emergence of new frequency components (har-
monics) which are close to the frequency of lamellae
generation, with periodic occurrence of self-excited vibra-
tions in the interval near tool end-of-life.

Acknowledgements
This paper presents a segment of the research on the
project number TR 35025. financed by the Ministry of
Education and Science of the Republic of Serbia, and
research over our of mobility and scholarships in the scope
of the network CEEPUS III RO 0202. University of Novi
Sad, Faculty of Technical Sciences.


Assist. Prof. Anti Aco, Dr.Sc.,
Prof. Kovacevi Dusan, Dr.Sc.,
Assist. Milosevi Mijodrag, M.Sc.,
University of Novi Sad,
Faculty of Technical Sciences,
Street Trg Dositeja Obradovia 6, 21000 Novi Sad,
Serbia
E-mail: antica@uns.ac.rs
dusan@uns.ac.rs
mido@uns.ac.rs
Prof. Novak-Marcincin Jozef, M.Sc., PhD.,
Technical University of Kosice,
Faculty of Manufacturing Technologies,
Street Sturova 31, 080 01 Presov,
Slovak Republic
E-mail: jozef.marcincin@tuke.sk




















Prof. Ungureanu Nicolae, M.Sc., PhD.,
North University of Baia Mare,
Machine Manufacturing Department,
Street Dr. V. Babes 62/A, 430083 - Baia Mare,
Romania
E-mail: unicu@ubm.ro




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