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Identification of common sensory features for


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Article in International Journal of Machine Tools and Manufacture July 2003
Impact Factor: 3.04 DOI: 10.1016/S0890-6955(03)00087-7

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International Journal of Machine Tools & Manufacture 43 (2003) 897904

Identification of common sensory features for the control of CNC


milling operations under varying cutting conditions
Yalcin M. Ertekin a, Yongjin Kwon b, Tzu-Liang (Bill) Tseng a,
a

Department of Architectural and Manufacturing Sciences, Western Kentucky University, Bowling Green, KY, 42101-3576, USA
b
Department of Mechanical and Industrial Engineering, The University of Iowa, Iowa City, IA, 52242-1527, USA
Received 18 December 2002

Abstract
The main focus of this study is to identify the most influential and common sensory features for the process quality characteristics
in CNC milling operationsdimensional accuracy (bore size tolerance) and surface roughnessusing three different material types
(6061-T6 aluminum, 7075-T6 aluminum, and ANSI-4140 steel). The materials were machined on a vertical CNC mill, retrofitted
with multiple sensors and data acquisition systems, to investigate the effects of variations in material types and machining parameters.
The sensor data include cutting force measurements, spindle quill vibration, and acoustic emission, each of which further divided
into measurable components, such as x, y, and z components in cutting force, x and y spindle quill vibration, DC, AC, and Count
Rate for acoustic emission signals. Those components were filtered and analyzed to determine the sensory features that best correlate
with process quality characteristics. Tool wear rate and machining characteristics appeared differently, depending on the material
types, yet some components of the sensory data were found to be significant with relation to the variations in bore size and surface
roughness for all three types of materials. This suggests that even under the varying cutting conditions involving different materials,
the identified sensory features can be used for the reliable and accurate control of milling operations.
2003 Elsevier Science Ltd. All rights reserved.
Keywords: Multiple sensor fusion in milling; Common sensory features; Varying cutting conditions

1. Introduction
The intense international and domestic market competition has driven the attention of manufacturers on automation of manufacturing systems as means for increasing the productivity and improving the quality of
products. This increasing trend towards automation has
created a need for the manufacturing industry to develop
a comprehensive approach to the problem of assuring
the quality [1]. To successfully obtain a component of
the correct size and surface finish the first time from an
automated system, a real-time machining process monitoring and diagnostic system is needed to integrate quality assurance into manufacturing processes. Such a
monitoring system must also replicate the overseeing
function and qualitative judgment of the expert machin-

Corresponding author. Tel.: +1-270-745-6951; fax: +1-270-7455946.


E-mail address: bill.tseng@wku.edu (T.-L. Tseng).

ist. Present quality assurance methodology based on


post-process monitoring offers detection only after the
fact, hence a number of nonconforming parts may have
been produced between manufacturing and inspection.
Rework of any rejected feature increases manufacturing
cost and can be very difficult to accomplish. In the case
of tool failure, costly damage to the machine tool and
workpiece will occur. An in-process real-time monitoring technique based on sensory input is therefore needed
to overcome these problems. In todays competitive
manufacturing environment, a small batch size and a
variety of products, a combination that is typical for
CNC machining, demand an increasing number of
diverse processes [2]. In batch production companies, it
is a common practice that tools are used interchangeably
to cut various parts made of different materials, using
disparate machining parameters. In such an environment,
the identification of common sensory features that best
correlate tool wear condition with process quality
characteristics for various material types has not been
adequately studied. To address the problem, CNC mill-

0890-6955/03/$ - see front matter 2003 Elsevier Science Ltd. All rights reserved.
doi:10.1016/S0890-6955(03)00087-7

898

Y.M. Ertekin et al. / International Journal of Machine Tools & Manufacture 43 (2003) 897904

ing operations on a vertical CNC mill retrofitted with


multiple sensors and data acquisition systems were conducted to find the most influential and common sensory
data with regard to the surface roughness and the bore
tolerance for three types of materials (see Fig. 1).
The materials (6061-T6 aluminum, 7075-T6 aluminum, and ANSI-4140 steel) and different settings of cutting parameters were intended to simulate diverse processes. Sensor data include cutting force measurements,
spindle quill vibration, spindle acceleration, and acoustic
emission (AE). Each measurement was further divided
into components: x, y and z cutting forces (Fx, Fy, and
Fz), x and y spindle quill vibrations (Ax and Ay), continuous AE signal (AEAC), DC AE signal (AEDC) and AE
count rate (number of threshold crossings). Those
components were filtered and processed for both time
and frequency domain features. Using the statistical
analysis techniques, some components of sensory data
were found to be the most influential factors to the variations in bore size and surface roughness, which can be
applied for all three types of materials. Therefore, the
identified sensory features can be used for the control
of milling operations more reliably and accurately under
varying cutting conditions. The main effort of this study
is focused on three topics: (1) cutting experiment and
multi-sensor data acquisition; (2) signal processing, data
reduction, analysis and feature selection; and (3) mul-

tiple regression analysis of multi-sensor data with surface roughness and bore tolerance. The listed topics are
presented in the subsequent sections and the findings and
analytical results are summarized in the conclusion.

2. Experimental setup, multi-sensor data


acquisition and processing
The main purpose of any machining operations is to
produce a desired part size, shape, and surface finish by
removing unnecessary materials. Two important quality
characteristics are often the dimensional accuracy and
the surface roughness. Surface roughness is as important
as the dimensional accuracy because it ensures proper
functioning and long life of machined parts [3]. In metal
cutting, the mechanics of material removal is a complex
phenomenon, yet the surface roughness and dimensional
accuracy can be controlled by adjusting three primary
machining variables: cutting speed (CS), feed rate (F),
and depth of cut (DOC). The control is possible because
(1) the variables are easy to adjust and have a definite
influence on the quality characteristics, and (2) much
machining and empirical data derived from the cutting
experiments are readily available. Surface roughness and
dimensional accuracy are also affected by other variables, such as cutting temperature, coolant, cutting force,
tool wear, machining dynamics and stability, work
material hardness and ductility, chip formation, chatter,
vibration, tool geometry and material, rigidity and damping characteristics of machine tool, and ambient temperature [4]. Some of the variables are difficult to measure on-line because of the lack of reliable sensors or
complexity in implementing sensors in a machine tool.
Sometimes, the temporal and random behavior of variables makes it very hard to define any meaningful
relationship with surface roughness and dimensional
accuracy. For example, the surface roughness (Rai) is
dependent on a number of variables (Xi, . . ., Xn) that
can be divided into four groups. The changes in the surface roughness (Rai) is an overall effect resulting from
the changes (Xi, i = 1, . . ., n) in the variables, represented in the following form (applied from Ronen
(1988) [5]):
Rai

Rai

Xi
Sj

Xi
j1
H

jL1

Fig. 1.

Experimental set-up.

Sj

Xi

Xi

Sj

jH1

Xi
Xi

jQ1

Sj

(1)

Xi
Xi

where Sj = sensitivities associated with each variable,


Sj0. The first group includes the variables, such as
cutting speed, depth of cut, feed rate, cutting force, and
tool wear, that are actually measured and their effect on
the surface roughness are considered. The second group

Y.M. Ertekin et al. / International Journal of Machine Tools & Manufacture 43 (2003) 897904

comprises variables that can be isolated from the experiment [5], which includes the flow of coolant, utilization
of chip breaker, work-holding devices, and selection of
tool types. By controlling those variables, one can isolate
or nullify their effects on the surface roughness. The
third group is a source of systematic uncertainty that is
neither measured nor isolated, yet their effects cannot be
neglected [5], including variations in machine repeatability, machine vibration and damping, cutting temperature, chip formation (chip geometry), chip exit speed,
variations in work material, cutting inserts, thermal
expansion of machine tool, and spindle motor power
consumption. The fourth group is also a source of systematic uncertainty, yet the effects here are assumed to
be very small or negligible [5], including room temperature, humidity, the amount of dust in the air, and fluctuations in the power source. Controlling and measuring
all the variables are infeasible, hence only the fraction
of the variables are ever measured and their relationships
with machining quality characteristics are derived. This
is referred to as a machining process model that represents a mapping of input and output variables for specific machining conditions [6].
In machining, the formulation of accurate mathematical models is very difficult, hence in most cases, empirical equations are obtained by performing statistical
analysis or through the training of neural network models to fit the experimental data. To collect the data, a
designed experiment is performed using predetermined
values of machining parameters. Even though empirical
equations do not consider the underlying principles and
mathematical relationships [7], empirical modeling does
have advantages of accuracy and ease of formulation [6].
One noticeable drawback of any empirical modeling is
the rigidity (narrow scope) that allows only limited variations in the machining conditions. That is, the cutting
conditions must be carefully controlled to remain similar
to those used in the cutting experiments. Cutting
materials from different batches may considerably
degrade the accuracy of the model since variations in
raw materials (e.g., hardness, strength, microstructure,
heat treatment conditions, and thermal properties) exist
between workpiece to workpiece or lot to lot [7]. Development of empirical models often leads to a large number of trials and a considerable amount of time and
effort, however, whenever variations occur, empirical
models need to be refitted to maintain the accuracy. To
avoid costly reproduction of cutting experiments under
the diverse production environment, while satisfying the
quality characteristics of the machined products, reliable
and accurate means of tool condition monitoring and
process control become necessary. Excellent reviews of
in-process monitoring techniques, classified as direct and
indirect techniques, have been made by many
researchers [8,9,10]. Indirect monitoring infers the tool
condition monitoring while machining is taking place so

899

that on-line implementation is possible. The main purpose is to prevent tool breakage. Various indirect monitoring techniques have been proposed, but most of them
have been limited to tool wear monitoring and tool
breakage detection using various process variables such
as cutting force [11,12,13,14,15,16], vibration
[17,18,19], temperature [20], acoustic emission
[21,22,23,24] and displacement [25]. The direct in-process monitoring techniques are of rather limited use and
sometimes unacceptable due to their slow down of the
manufacturing cycle.
In this study, all machining experiments were conducted on a Cincinnati Milacron Sabre-750 CNC vertical
machining center at Cincinnati Milacron Regional Technical Center in Arlington Heights, Chicago, IL. The
experimental set-up is shown in Fig. 1 and the drawing
of the machined components and its dimensions are
shown in Fig. 2. The components were machined from
6061-T6 Al, 7075-T6 Al, and ANSI-4140 steel blank
workpieces of size 130 mm 100 mm 63.5 mm. A
25.4 mm-diameter cobalt high speed steel (HSS) drill
was used to drill a starting hole. Then, a 25.4 mm-diameter, 2-flute cobalt HSS end mill was used to mill the
84 mm 84 mm square and the 70, 65, and 50 mm
bores. Fresh tools were assigned for each material and
the cutting continued until tools wore out. Up milling
was used to machine the square and down milling for
the three bores. Machining was done in the following
order: drill a 25.4 mm hole, rough mill the 84 mm 84

Fig. 2. Drawing of the machined component.

900

Y.M. Ertekin et al. / International Journal of Machine Tools & Manufacture 43 (2003) 897904

mm square, rough mill the 70, 65 and 50 mm bores,


finish face (3 mm DOC), and finish mill the 70, 65 and
50 mm bores. The cutting parameters and material hardness are provided in Table 1.
Multi-sensor data (acoustic emission, cutting force
components and spindle quill vibration (acceleration))
were acquired simultaneously during the finishing pass
for the 50 mm bore when the end mill was at about 225
from the positive x-axis (as illustrated in Fig. 2). A
Kistler three component force dynamometer (type
9257A) on which the workpiece was mounted sensed
the dynamic cutting force components (Fx, Fy and Fz).
Previous research (Dontamsetti and Fischer (1988) [26])
has shown that root mean square (RMS) values of the
vertical component of the cutting force (Fz) remains
fairly constant during machining, thus is not considered
in this study. The two force components (Fx, Fy) were
passed through a Kistler three component charge amplifier type 5004 and acquired by a Norland IQ400 two
channel data acquisition and analysis instrument. The
sampling rate was 10 kHz and 2048 sample points per
signal were acquired. All the cutting force signals were
passed through a built-in digital filter in the Norland
IQ400 data acquisition system using a bandpass of 0 to
1000 Hz to better isolate the characteristics at the cutter
tooth frequency of 70, 35, and 23.33 Hz. The raw cutting
force data were transformed into a frequency domain
using Fast Fourier Transform (FFT) techniques. Cutter
tooth frequency ft was calculated using the equation:
ft

N
n
60

(2)

where N = spindle RPM and n = the number of teeth on


the cutter. For instance, 6061-T6 Al has N of 2100 rpm
and n of 2, so ft was calculated to be 70 Hz. The acceleration signals were filtered on-line during data acquisition
by a low pass filter with an upper cutoff frequency of
1500 Hz.
AE from the cutting process was sensed using a B&K
AE resonance transducer, type 8313, having a resonance
frequency of 200 kHz. The transducer was attached to
the spindle quill. A B&K accelerometer model 4371
with mounted natural frequency of 42 kHz was used to
sense the vibration (acceleration) of the spindle in the x
and y-axis directions. The spindle quill has been found
to be the most practical and sensitive location for AE

and vibration sensors in milling [13]. The AE signals


were recorded simultaneously in three forms (AEAC,
AEDC, and AE count rate). AEAC and AEDC signals
were acquired by a Norland Prowler two-channel data
acquisition system. Again, 2048 sample points per signal
were acquired with a sampling rate of 1 MHz. The AE
count rate and spindle vibration were recorded using a
Nicolet two-channel data acquisition system with a sampling rate 10 kHz and 4000 sample points per signal.
The AE signals were passed through a preamplifier with
a 40 dB gain and 200 kHz octave bandwidth filter. The
preamplified signals were further processed by a wideband conditioning amplifier wherein further filtering and
amplification (49 dB) was done before being recorded
by the data acquisition system. An automatic triggering
(built in-house) was used for automatic triggering for
data acquisition. The 50 mm bore has the tightest tolerance of 0.1 mm, corresponding to an ISO tolerance
grade of IT10 and surface roughness of 1.2 m, hence
a 0.1 mm bore tolerance and 1.2 m surface roughness
of the 50 mm bore were chosen as the critical quality
characteristics for process monitoring. RMS values of
the acquired multi-sensor signals were calculated, since
RMS values were found to be correlated with part quality characteristics [26]. The tolerances of the 50 mm bore
were measured using a Brown & Sharpe coordinate measuring machine, and the bore surface roughness in the x
and y directions were measured using a Perthen profilometer type C5D. These data were analyzed later to
study the correlation between the sensory features and
the tool wear (workpiece number) and part quality
characteristics. The number of milled components for
6061-T6, 7075-T6 aluminum and AISI-4140 steel were
19, 25, and 17, respectively.

3. Experimental results and data analysis


In this section, results of the measured part quality
characteristics, multi-sensor data characterization, and
regression analysis are presented. The measured surface
roughness (Ra) for all the machined components are
shown in Fig. 3. Two surface roughness measurements
(Rax and Ray) were made for each component. The arithmetic average roughness along the x-axis of the machine
tool is denoted as Rax and similar measurement along

Table 1
Cutting parameters and material types used in the experiment
Material

Brinell hardness Spindle speed


(rpm)

Cutting speed
(m/min)

6061-T6 Al
7075-T6 Al
4140 Steel

95
150
200

168
84
28

2100
1050
350

Feed rate
(mm/min)
304.8
101.6
25.4

Radial depth of
cut (mm)
6
12.7
3

Axial depth of
cut (mm)

Cutter tooth
frequency (Hz)

12.7
30
3

70
35
23.33

Y.M. Ertekin et al. / International Journal of Machine Tools & Manufacture 43 (2003) 897904

Fig. 3. Surface roughness vs. WPno.

the y-axis is denoted by Ray. The arithmetic mean of Rax


and Ray is also calculated and denoted as Ra. The results
show that the two measurements Rax and Ray are similar;
therefore, any one measurement could be used. The
measurements plot (Fig. 3) shows the dependence of the
tool wear on cutting time that can be divided into three
general regions: an initial rapid breakdown period; a uniform wear rate period; and a rapidly increasing
(destructive) wear region [4,27,28].
The plot of the bore tolerance (Tol) versus workpiece
number (WPno) is shown in Fig. 4. The bore tolerance
increases negatively and linearly with WPno (tool wear).
When the cutting progresses, the tool diameter becomes
smaller due to wear and the bore diameter gets smaller
than the nominal size of 50 mm. Consequently, the bore
tolerance eventually exceeds the design tolerance of
0.1 mm (as shown in Fig. 4 after workpiece number
11 for 4041 steel). The BUE also has a negative impact
on dimensional accuracy of the machined part, since it
changes the uncut chip thickness during machining. For
4041 steel, a linear curve fit models the data with a cor-

Fig. 4.

Bore tolerance vs. WPno.

901

relation coefficient of R2=0.91 (the regression equation


is given as: Tol=0.0094590.009855 WPno). The slope
of this line is related to tool wear rate or tolerance
deterioration rate per workpiece and is found to be
0.009459 mm/WPno. This tool wear rate (tolerance
deterioration rate) information could be used to plan the
time for tool change or machine reset.
For cutting force time domain analysis, the RMS and
mean values of Fx, Fy and Fv were calculated. The plot
of mean values of the cutting force components shows
no meaningful trend and therefore not given here nor
considered further. The data points are too scattered and
no conclusion can be drawn from the data. This is in
agreement with observations in previous work [29]. The
RMS values of Fy in Fig. 5 follow the wear pattern for
cutting tools mentioned earlier. The initial wear-in period is clearly seen between WPno 1 and 4, then the uniform wear rate period of Region II (WPno 514) after
which the plot tends to flatten. Region III of destructive
wear is not obvious; perhaps tool wear has not reached
that stage. The increasing trend in Fy component of the
cutting force is mostly due to flank wear of the tool.
Increasing abrasion at the cutting toolworkpiece interface leads to higher friction, which causes higher cutting
force in the y-axis direction with increasing cutting time
(progressive tool wear). The Fx plot in Fig. 5 shows an
interesting decreasing trend, indicating a dominant crater
wear on the tool rake face. Both BUE and crater wear
change the cutting tool geometry, thus the cutting forces
in the x-axis direction (Fx) decreases, assuming the shear
stress on the shear plane remains constant [14,30,27].
Ultimately, flank wear will have a dominant effect and
Fx starts to slightly increase after workpiece number 17.
Since the Fy cutting force is more sensitive to tool wear,
it becomes the dominant trend in the Fv. Consequently,
an increasing trend in Fv is seen from Fig. 5, as well as
the RMS of other Fv values in Fig. 6. The power spectral
magnitudes at the cutter tooth frequency were plotted
with WPno (tool wear), showing similar trends to those

Fig. 5.

RMS of cutting force components vs. WPno.

902

Y.M. Ertekin et al. / International Journal of Machine Tools & Manufacture 43 (2003) 897904

Fig. 6.

Fv vs. WPno for three material types.

observed in the time domain analysis (RMS values) of


the cutting force components. Therefore, monitoring the
data in the time domain is sufficient to predict tool wear
condition. This result is important for implementation of
the real time tool condition monitoring system because
of the high cost of the frequency spectrum analyzer.
The spindle quill vibration (acceleration) was measured in the x-axis (Ax) and y-axis (Ay) directions of the
machine tool. The plot of RMS of Ax versus WPno in
the time domain is given in Fig. 7. It is clearly seen that
the spindle quill vibration signal is changing randomly,
yet showing a nonlinearly decreasing trend (an obvious
reduction in amplitude with machining time as the tool
wears out). Several other researchers observed a similar
phenomenon in the acceleration power spectrum
[30,18,20,17]. This decreasing trend is mostly attributed
to the flank wear characteristic of the cutting tool and
dynamic characteristic of the harder workpiece material.
When the tool cutting edge is new, the contact between
the tool and workpiece is restricted to an almost line
contact, thus it offers a small amount of resistance to the
oscillations of the tool and workpiece. On the other hand,
as flank wear land progresses with machining time, the
larger contact area increases the amount of workpiece

Fig. 7.

RMS of spindle quill acceleration vs. WPno.

material being elastically deformed, thus increases the


frictional damping. When the flank wear exceeds a certain amount, the stronger excitation caused by the larger
cutting force becomes dominant, with a consequent
increase in the vibration (acceleration). In fact, this point
is seen in Fig. 7 after workpiece number 17 as a slight
increase in the total RMS value of the spindle quill
acceleration signal. Another important observation is
that the changes in the cutting force signal Fx are directly
reflected in the respective spindle vibration signal Ax,
indicating that the sensitivity of the cutting force and
spindle quill acceleration to changes in the WPno (tool
wear) would be very close to each other. The spindle
quill acceleration data were transformed into the frequency domain using the FFT technique. For 7075-T6
Al, the peak magnitude is at the cutter tooth frequency
of 35 Hz and also a peak at approximately 180 Hz (the
5th harmonic of the 35 Hz). Here also, the peak magnitude at tooth frequency is higher for the 1st workpiece
than for the 25th workpiece, which follows decreasing
trends with workpiece number similar to that observed
in time domain analysis. This trend was the same for the
other two material types.
When most materials are strained, deformation of the
molecular structure takes place. Short impulsive stress
waves that are generated at a failure source propagate
through the structure and can be detected at its surface
by an acoustic emission (AE) transducer. Several sources
of AE in the metal cutting process are [23]: (a) deformation in the shear zone; (b) deformation and sliding
friction at the chiptool interface; (c) sliding friction at
the tool flankworkpiece interface; and (d) the breaking
of chips and their impact on the cutting tool or workpiece. During our machining experiments, a resonant
type of AE sensor was attached on the spindle quill of
the CNC mill. Three types of AE signals (AEAC, AEDC
and AE count rate) were recorded. Sensor signals for
AEAC, AE count rate and AEDC are analyzed, showing
that AEAC is stationary. The peak to peak value of
AEAC signal is higher for higher workpiece numbers,
indicating increasing energy in the signal. A similar
increase is observed in the AE count rate signal. An
increase in the AEDC signal from 0 to approximately
9000 mv is observed for 4140 steel. In order to determine the energy of the AEAC and AE count rate signals,
RMS values of the signals were calculated and plotted
versus WPno. The background noise has an RMS value
which remains constant and any variation of the RMS
above this value indicates AE occurring from the machining process. DC power of the AE signal was also calculated using the AEDC signal and plotted against WPno.
By analyzing the plots of 3 AE signals, the most sensitive to tool wear is found to be the AEDC signal. A
continuous increase in AEDC power is observed as
machining continues. Because of the superior sensitivity

Y.M. Ertekin et al. / International Journal of Machine Tools & Manufacture 43 (2003) 897904

to tool wear, the AEDC signal was selected as the sensory feature for multiple regression analysis.
In Sections 3.1 and 3.2, the case of 4140 steel is
presented, rather than providing a detailed description
for each material. It is because the steel is much harder
than the aluminums and the machining characteristics
appear to be more unstable (higher wear rate, rougher
surface finish, wider tolerance distribution due to larger
cutting force and bigger tool deflection, heavier
vibration, etc.) than those of the aluminums.

903

sion indicate the negatively highest bore tolerance value.


Increasing Fv when AEDC is low indicates a negatively
lower bore tolerance value. High AEDC and low Fv indicate a peak point (negatively) for bore tolerance. This
also suggests that the combination of the two sensors is
more sensitive to the deterioration of the cutting
tool/workpiece condition, hence the integration of the
two sensors will provide a more reliable and accurate
prediction of the bore tolerance than when using a single
sensor feature.

3.1. Multiple regression of Ra on Fv and AEDC


4. Conclusions
Multiple regression analysis was obtained using surface roughness (Ra) as the dependent variable. The quality characteristic is the Ra of the 50 mm bore. Using
the forward elimination technique, the common sensory
features for all three material types were found to be the
Fv and AEDC. The 4041 steel has the highest R2 values
of 0.99 and is in the form of:
Ra 32.69430.602 Fv 0.003865 F2v
8.26 106 F3v 0.7151 AEDC
0.2141 AEDC2

(3)

0.0146 AEDC3.
This indicates a very high correlation between Ra and
Fv and AEDC. The regression equation plot shows that
when there is a very low Fv in the machining process,
the highest surface roughness value is observed. Another
interesting observation is that AEDC response is insensitive to changes in surface roughness until the Fv reaches
approximately 163 N. Then, the AEDC starts becoming
sensitive. A simultaneous increase in both RMS values
of the Fv and AEDC indicate higher surface roughness
values, again showing the importance of monitoring
more than one process variable simultaneously in real
time. Their integration gives a more reliable and accurate
prediction of bore tolerance than when using a single
sensory feature.
3.2. Multiple regression of bore tolerance on Fv and
AEDC
Multiple regression analysis was done using bore tolerance (Tol) as the dependent variable. The quality
characteristic is the Tol of the 50 mm bore. Using the
forward elimination technique, the common sensory features for all three material types were again found to be
the Fv and AEDC. The best model is in the form of:
Tol 8.532880.1749 Fv 0.001163 105 F2v

(4)

2.543 106 F3v0.000597 AEDC2,


where R2 = 0.89 in the case of 4140 steel. The regression
equation plot shows that low Fv and high AEDC emis-

From the analysis of experimental results for all three


types of materials, the following observations are made.
The relationship between Ra and machining time (WPno)
indicates a typical tool wear versus machining time
curve. Therefore, Ra measurements can reliably be used
as an indirect criterion, estimating tool wear states and
for monitoring the performance of the machining process. The bore tolerance of the machined components
linearly deteriorates with machining time. The slope of
bore tolerance vs. WPno gives the tolerance deterioration
rate and this information could be used to plan the time
for tool change. Since both bore tolerance and Ra reach
their specified acceptable limits at different times, it is
important to monitor simultaneously both quality characteristics to assure the quality of the circularly milled part.
The means of cutting force components and spindle quill
acceleration do not show any meaningful trend and are
not suitable for tool condition monitoring. Power spectral amplitudes at the cutter tooth frequency (70, 35, and
23.33 Hz) of both cutting force and spindle quill acceleration signal were found to be very sensitive to progressive tool wear and recommended as suitable sensory features for machining process monitoring. Frequency
domain analysis of the cutting force signals was found
to be very sensitive to progressive tool wear, similar to
the trend observed with the time domain analysis (RMS
values). This indicates that the time domain data can
reliably be used to predict quality characteristics of the
machined components, therefore eliminating the high
cost of frequency spectrum analyzers during the
implementation stage of the tool condition monitoring
system. RMS values of both Fy and Fv shows similar
increasing trends with respect to tool wear, whereas the
RMS values of Fx and the spindle quill accelerations (Ax
and Ay) decrease with progressive tool wear. Among the
three acoustic emission signals, AEDC was found to be
the most sensitive against progressive tool wear. Three
of the AE components give increasing trends with
increasing machining time. For the common sensory features, the integration of RMS values of Fv and AEDC
was found to be the best to predict the quality characteristics of the machined parts for all three material types,

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Y.M. Ertekin et al. / International Journal of Machine Tools & Manufacture 43 (2003) 897904

showing that the integration of the two sensory features


gives a more sensitive and reliable prediction than a single sensory feature. For 4140 steel, a 3rd order multiple
regression model which uses Fv and Av gives a multiple
correlation coefficient of 0.70, whereas a 3rd multiple
regression of Fv and AEDC provides a better regression
coefficient of 0.99. The Fv and AEDC, identified as the
most influential factors correlated with the variations in
bore size and surface roughness, therefore, can be
applied for all three types of materials to achieve more
reliable and accurate control of milling operations under
varying cutting conditions.

[12]

[13]

[14]

[15]

[16]

Acknowledgements
The financial support of this work by the National
Science Foundations Manufacturing Machines and
Equipment program in the Division of Design and
Manufacturing Systems and Cincinnati Milacron Inc. is
gratefully acknowledged.

[17]

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