Relationship of Temperature and Cutting Force with Tool Wear and Vibration in Metal Turning

Introduction. The processes that occur in the machine when cutting metals are interconnected with each other. In the process of cutting, the complex dynamics of processing includes both rapidly changing factors and factors that are more evolutionary (slow) in nature. By such factors the following is meant: changes in stationary components of cutting forces, temperature in the processing zone and tool wear. There is no single and consistent mathematical model describing this connectivity today. Therefore, the paper proposes an approach based on the processing of experimental data obtained in a series of experiments, which allows to identify the structure of feedbacks formed during cutting and linking subsystems that describe the force, heat and vibration responses from the cutting process to the shaping movements of the tool. Purpose of work: Due to the formation of a consistent model of communication between subsystems that describe the force, heat and vibration responses from the cutting process to the shaping movements of the tool, to obtain a description of the mechanism of self-organization of the cutting process in the process of evolutionary changes of the tool. The resulting mechanism is needed to find a certain mode of operation of the cutting system, in which further wear of the wedge, cutting force, temperature in the cutting zone and tool vibration can be stabilized. The paper examines: the process of metal processing by cutting on a lathe for the case of longitudinal turning of the product. Research methods: the Research consists of a series of field experiments on real equipment using a modern measuring stand STD.201-1, which allows simultaneously measuring the force, temperature and vibration components of the reaction from the cutting process to the shaping movements of the tool. For processing and analysis of the experimental data obtained, a package of mathematical programs Matlab is used, in which a subroutine is developed that allows spectral analysis of vibration signals, as well as graphical interpretation of the measured values. Results and discussion. The results of processing experimental data, in particular, the spectra of vibration signals, obtained the dependence of forces and temperature on tool wear, and also revealed the effect of wear on the vibration dynamics of the cutting process. The influence of vibration energy of the tool on the temperature field in the cutting zone is estimated. The main conclusion of the work is the position put forward by us about the self-organization of the cutting system, through the process of tool evolution, which is expressed in the wear of the wedge, the purpose of which is the formation of a certain quasi-stationary cutting mode.