International Journal of Advances in Engineering Science and Technology

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59
ISSN: 2319-1112

Tool Condition Monitoring In Machining Using

Vibration Signature Analysis: A Review
Pranali S. Malgave 1, Prof.Dr. S. S.Kulkarni 2, Prof. A.P.Shrotri 3and Mr. A.R.Dandekar 4
1 P.G. Studet, Department of Mechanical Engineering, P.V.P.I.T Budhgaon, Sangli, Maharashtra, India.
2, Professor& P.G. Guide, Department of Mechanical Engineering, P.V.P.I.T Budhgaon, Sangli, Maharashtra, India
.
3 Associate Professor& P.G. Guide, Department of Mechanical Engineering, P.V.P.I.T Budhgaon,
Sangli, Maharashtra, India.
4Asst. Professor, Department of Mechanical Engineering, P.V.P.I.T Budhgaon, Sangli, Maharashtra, India.
1

jain.pranali.91@gmail.com
kulsat@gmail.com, Amod_shrotri@rediffmail.com,4ashutoshdandekar@gmail.com

,2

Abstract ;-The main trend of the machining industry is towards the production cost reduction by using higher cutting speeds
and by reducing human resources. The necessity of the latter is resulting into the development of unmanned machining
systems. Condition monitoring system, which is capable of identifying machining system defects and their location, are essential
for unmanned machining.
In this paper general tool maintenance techniques are discussed along with brief discussion on the tool condition
monitoring techniques. Different types of tool wear and their mechanisms are also studied. Different parameters affecting tool
condition are discussed.
Keywords: condition Monitoring, tool wear, Vibration signature analysis

I.INTRODUCTION:Condition monitoring, capable of identifying machining system defects and their location, is essential for
unmanned machining. The ability to monitor the condition of machines while in operation is very useful in preventive
maintenance of continuously operating machine. Continuous monitoring will find application with the most critical
machines, to guard against rapidly deteriorating situations and allow shutdown before catastrophic failure occurs.
There are various methods used for tool condition monitoring, mainly distinguished as direct and indirect methods.
Vibration signature analysis is one of the important methods which fall under indirect method.
Vibration signature represents a measurable symptom of a problem associated with rotating equipment which
results in destructive mechanism such as fatigue, stress or wear of concern equipments. Machines in good condition
generally tend to have a fairly stable vibration pattern. Changes in the internal conditions are often reflected by changes in
the vibration pattern which can then be detected by externally mounted pick-ups while the machine is in operation.

II.Literature review:
Tool wear condition is defined as the change of tool cutting geometry. Tool wear monitoring implies strategy
which, based on the sensor signals placed on the machining system, allow quick reaction to all out coming process
disruptions.
One of the most important components in a machining system is the tool. Unmanned production is possible
only if there is a method or a combination of methods available for tool condition monitoring (TCM). Tool wear
influences the quality of the surface finish and the dimensions of the parts that are manufactured, whereas tool failure is a
major cause of unplanned interruption in a machining environment. Tamizharasan and Senthil Kumar[1] evaluated the
effect of tool geometries on performance measures of flank wear, surface roughness and cutting forces. They applied
finite element analysis to minimize flank wear of uncoated carbide inserts during machining. Taguchis DOE is used to

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design the experiment. A machining simulation and analysis and the output quality characteristic are analyzed by
statistical techniques like signal to noise ratio and ANOVA. Optimum conditions are obtained for three parameters
namely insert shape, nose radius and relief angle. More tool geometrical parameters are considered as a future scope to
improve the performance of cutting inserts.
Several technologies and studies are involved in the study of tool condition monitoring systems (e.g., cutting
mechanism in machining, tool wear mechanism, signal processing, etc.). In this Paper, five main topics are discussed.
First, General machine maintenance techniques will be discussed. Second, the tool condition monitoring techniques will
be introduced. Third, the mechanism and properties of turning operations and tool wear are discussed. Fourth Parameters
affecting tool condition will be discussed. Fifth, Vibration Signature Analysis will be introduced.
II.a. MACHINE MAINTENANCE TECHNIQUES
The life of machine follows the bathtub curve shown in fig. 1. Since there is a direct relationship between
Failure probability and vibration level, vibration level also follows the shape of the same bathtub curve. The vibration
level decreases during the initial period, then increases very slowly during the normal operating period due to the normal
wear, and finally increases rapidly due to excessive wear until failure or breakdown in the wear out period[2].
Three types of maintenance scheme can be used in practice;
1. Breakdown maintenance: The machine is allowed to fail, at which time the failed machine is replaced by a
new one. This strategy cant be used if the machine is expensive to replace and the breakdown causes any
other damage.

2.

3.

Fig. 1: The bathtub curve for the life of a machine.

Preventive maintenance: Maintenance is performed at fixed interval of time such as every 2000 operating
hours or once a year. The maintenance intervals are usually determined from past experience. This method
reduces the chance of unexpected breakdowns, but it has been found to be uneconomical. The stoppage for
maintenance involves lost production time and also a high risk of introducing imperfections due to human
error. In addition, the probability of failure of a machine component cant be reduced by replacing it with a
new one during the normal wear out period.
Condition-based maintenance: The fixed intervals of time are replaced by fixed interval measurements that
permit the observation of changes in the running condition of the machine regularly. Thus the fault
conditions can be detected and their development is closely followed. The measured vibration can be
extrapolated in order to predict when the vibration levels reach non tolerable values and when the machine
must be serviced. Hence, this method is also known as predictive maintenance. In this method the
maintenance costs are greatly reduced due to fewer catastrophic failures, better utilization of spare parts, and
elimination of the unnecessary preventive maintenance. The vibration level (and hence the failure
probability) of the machine due to condition based maintenance follows the shape indicated inFig.2.

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Pranali S. Malgave

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Fig. 2: Condition based maintenance.

Tool condition monitoring (TCM) methods can be categorized into several. In-process (In-line) TCM
studies detect the amount of tool wear during the cutting process. Off-process (Off-line) TCM studies detect
the amount of tool wear at the end of the cutting process. TCM systems also may be grouped into direct
systems and indirect systems, based on the type of sensor technology used.
Erkki Jantunen[4] has summarized the different direct and indirect methods applied to tool condition
monitoring. P.N. Botsaris and J.A. Tsanakas [5] have reviewed the state of art in methods applied to tool condition
monitoring.Tadic B. et. al. [6] have explained how approach based on indirect methods of condition monitoring has
advantages over direct methods.
II.b . STUDIES OF TOOL CONDITION MONITORING
Table 1: Differentiating Points of Direct and Indirect Methods

Direct Method

Indirect Method

Collect information or signals from the tool itself

Sense secondary details of the cutting process

Information is directly related with amount of tool

wear
Could not be used on-line

No direct relationship between the signals and

the amount of tool wear
Optimal for integration into in-line systems

Affected greatly by the presence of other materials

Presence of other materials does not affect

considerably
Measurement of Acceleration, Vibration,
Force, Surface texture, etc.

Measure the tool wear directly by means of tool

images, computer vision etc.

Castejon et. al.[7] have made use of geometric descriptors from digital images for on-line tool wear
monitoring. He has studied a new method based on a computer vision and statistical learning system which is proposed to
estimate the wear level in cutting inserts in order to identify the time for its replacement. Abellan-Nebot[8] has reviewed
machining monitoring systems based on artificial intelligence. He has reviewed application of various sensor systems and
techniques for signal processing in building laboratory systems for tool wear monitoring. He analyzed various design
solutions in terms of the number and types of sensors. H. Chelladurai et. al.[9] has developed the cutting tool condition
monitoring system for high speed turning operation by vibration and strain analysis. The problem of detection of flank
wear in turning operation has been studied using vibration and strain measurement methods. An attempt has been made to
create artificial flank wear using the electrical discharge machining (EDM) process to emulate the actual or real flank
wear. T. I. El- Wardany et. al.[10] has used the vibration signature analysis to monitor the tool condition in drilling.
Discriminate features, which are sensitive to drill wear and breakage, wear developed in both time and frequency domain.

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K. Jemielniak[11] has presented the state of the art in commercially available tool condition monitoring sensors and
comparatively studied it.
II.c. PARAMETERS AFFECTING TOOL CONDITION
This section briefly introduces different parameters affecting the condition of the tool. These parameters are broadly
classified into two groups, first, machining parameters and second, tool parameters.
Machining parameters:
The machining parameters that determine the rate of metal removal are cutting speed, feed rate, and depth of cut.
The combination of machining parameters and the characteristics of the material to be cut determine the power required
to make the cut. The machining parameters must be selected to stay within the power available on the machine tool to be
used. Since there is a direct relationship between tool life and machining parameters (tool life is reduced when cutting
speed is increased), the tool life also should be considered when determining the machining parameters. Figure 2.1 shows
the machining parameters of the turning operation [3].
The available power must be sufficient to make the required depth of cut at the finish should be selected. The
third step is to select the cutting speed. Although many machining handbooks provide a recommended combination of
cutting speeds and feeds for many materials, an experienced operator often will adjust the combination based on the
workpiece and tool materials to obtain optimal surface characteristics and efficiency. However, in general, the depth of
cut is selected first, followed by the feed, and, finally, the cutting speed.

Fig 4: Schematic illustration of turning operation

In this study, a general range of spindle speed, feed rate, and depth of cut were discussed with combinations of
the tools that have different amounts of wear.
III.TOOL PARAMETERS:
Tool Geometry
Machining is one of the most important and common manufacturing processes in industry. The efficiency and
effectiveness of the machining process can be increased, by continually improving the carbide cutting tool insert
geometries.The geometrical parameters of cutting tools that significantly affect the tool condition under given machining
conditions in terms of tool life, surface finish etc. are:

Tool rake angles () : Positive tool rake angle sharpens the tool, so decreases strength. Negative rake angle
decreases sharpness of tool so, increases strength.
Clearance angle Fig. 3.1.5 schematically shows how clearance angle, affects tool life.

Fig. 5: Influence of tool clearance angle on tool life.

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Pranali S. Malgave

Cutting angles ( and 1) : influences transverse force ang cutting temperature.

Nose radius (r)
Proper tool nose radius improves machinability to some extent through

Increase in tool life by increasing mechanical strength and reducing temperature at the tool tip

Reduction of surface roughness
Proper edge radius (r) also often enhances strength and life of the cutting edge without much increase in cutting
forces.
Tool material:

Physical and chemical properties of work material influence tool life by affecting form stability and rate of wear of tool.

Fig. 6: Role of cutting tool material on tool life

Other parameters which might be monitored for condition Monitoring are given below:
Axis drive motor current/power
Feed drive current
Acceleration
Surface texture
Temperature
Distance/Displacement
In this study, different parameters affecting tool condition were introduced in two categories.
Out of these parameters two parameters named clearance angle (), rake angle () and nose radius (r) will be monitored to
develop the tool condition monitoring system. The machining parameters such as cutting speed, depth of cut and feed rate
will be kept constant.
IV. VIBRATION SIGNATURE ANALYSIS
It is a fact that an experienced mechanic can predict by ear the development of many faults in for example an
automobile engine, to the extent that the sound "signatures" of many such faults have acquired standard names: "bearing
knock", "pinging" etc. The concept of "vibration signature analysis" is in principle verysimilar: machines in good
condition generally tend to have a stable vibration pattern, which can be considered as a signature.T. I. El- Wardany et.
al.[10] has used the vibration signature analysis to monitor the tool condition in drilling. Discriminate features, which are
sensitive to drill wear and breakage, wear developed in both time and frequency domain. S.K. Acharya et. al.[12]
presented an overview of Tarapur Atomic Power Station 1&2 (TAPS) condition monitoring and performance evaluation
on the basis of vibration signature analysis of rotating equipments at TAPS 1&2 with some case studies and concluded

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that the vibration signature analysis is very important diagnostic tool for reliability centred maintenance. M. S. H.
Bhuiyan et. al.[13]have made use of Acoustic Emission and Vibration Signature to monitor tool condition in Turning.
V. CONCLUDING REMARK:
This Paper reviewed the literature related to machine maintenance techniques, condition monitoring, tool
wear mechanism, Parameters affecting tool condition and vibration signature analysis.
Based on study of available literature following conclusions are drawn on current state of development in area
of Tool Condition monitoring (TCM).
 It is noticed that all available methods present some drawbacks and limitations. Most effective and reliable methods
for tool wear monitoring are so slow in practice that they are not suitable for the detection of sudden failures. Thus, it is
vital to minimize the complexity of TCM system.
 There is a need to develop a condition monitoring system for varying cutting conditions. The effect on machine
performance, complexity and cost has to be taken under consideration while developing an effective tool condition
monitoring system.
 Among all indirect methods used for tool condition monitoring Vibration signature analysis technique is an
important one because, Vibration signals measured at the external surfaces of a machine contain a great deal of
information about the internal processes and a number of monitoring and analysis techniques can be applied to extract
information from these signals.
 None of the system, using indirect method of TCM,represents the condition of the tool on the level required for
industrial application.
 There is a need for a system, providing continuous, fast and accurate determination of tool condition which will
result inleast intervention in machining system. Such a system allow:
1.
Increase in capital equipment utilization,
2.
Provision of required workpiece dimensional accuracy and surface quality,
3.
Reductionin manufacturing costs.
4.
Reduction in downtime. Hence increase in productivity.
References:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

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