Authors: M Prakash M Kanthababu K P Rajurkar
Publish Date: 2014/11/12
Volume: 77, Issue: 5-8, Pages: 1499-1511
Abstract
This work investigates the effects of tool wear on surface roughness Ra chip formation mechanisms and chip morphology in the microendmilling of aluminum alloy AA 1100 using acoustic emission AE signals The acquired AE signals are analysed in the time domain frequency domain using fast Fourier transformation FFT and the discrete wavelet transformation DWT technique The time domain analysis indicates that the root mean square of the AE AERMS signals is sensitive to the formation of the buildup edge apart from effective machining The frequency domain analysis indicates that the dominant frequency of the AE signals lies between 150 and 300 kHz The AEspecific energies are computed by decomposing the AE signals in different frequency bands using the DWT technique The higher and lower orders of AEspecific energies are obtained The higher order of AEspecific energies indicates chip formation mechanisms such as shearing and microfracture Chip morphology studies are carried out using the FFT analysis The FFT indicates that lowfrequency and lowamplitude AE lead to tight curl chips while highfrequency and highamplitude AE lead to elemental/short comma chips This work provides new significant inferences on tool wear chip formation mechanisms and chip morphology in the microendmilling of AA 1100
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