Abstract: - On-line tool condition monitoring isessential for modern machining system, especially in the case the case ofprecision and unmanned machining. Knowledge of the condition and expected lifeof the tool are very important inputs for determining the optimal machiningparameters. On-line tool wear monitoring increases the cutting tool utilizationconsiderably and gives better surface quality; however, few reliable and robustindirect methods have yet been established for industrial use. This is mainlydue to the complexity of the machining process and uncertainty in thecorrelation between the process parameters and tool wear. So promising methodsare yet to be developed for detecting the tool wear. Ultrasonic technique isproposed for detecting the tool wear in machining process by online monitoring.Ultrasonic testing uses A-Scan to evaluate the depth, position and area of toolwear. Two types of wears affect the tool life namely flank & crater wear,during machining of ductile material crater wear dominates more. An integratedultrasonic transducer (Angle probe) operating at a frequency of 1-20 MHz isplaced in contact with the tool. The change in amount of reflected energy fromthe nose and the rake face of the tool can be related to the amplitude level,Time of flight and Root mean square value. This can be used to find the craterwear of the tool.
Keywords: Online Wear Monitoring System, Single PointCutting Tool, Ultrasonic Machining, Integration Ultrasonic Transducer