Integrated Monitoring of Surface Roughness and Chip Formation by Utilizing Cutting Force and Cutting Temperature

This research presents the integration of the surface roughness and chip formation monitoring by using the cutting force and the cutting temperature during the in-process turning. The surface roughness prediction model is proposed by utilizing the response surface analysis with the Box-Behnken design. The effects of cutting parameters on the cutting force and the cutting temperature are investigated. The cutting force and the cutting temperature are measured to help analyze the relation between the surface roughness and the cutting conditions. The models of the cutting force ratio and the cutting temperature are also proposed based on the experimental data. The in-process monitoring of chip formation is developed to detect the continuous chip and the broken chip by utilizing the power spectrum density of dynamic cutting force and the variance of the dynamic cutting temperature. The broken chip formation is required for the reliable turning operation. The algorithm is proposed to obtain the broken chip by changing the cutting conditions during the cutting process based on the cutting force and the cutting temperature. It has been proved by series of cutting experiments that the proposed surface roughness model can be effectively used to predict the surface roughness, and the broken chip is well identified by the proposed method.