Monitoring groove wear development in cutting tools via stochastic modelling of three-dimensional vibrations

This paper describes an experimental investigation into the patterns of groove wear development and their monitoring at the minor cutting edge of metal-cutting tools. It is shown that these grooves, once formed, adversely affect the dimensional accuracy and surface roughness in finish machining. Multivariate time series stochasticmodels are developed directly from vibration signals, measured with a miniature three-dimensional (3D) accelerometer mounted in close vicinity to the tool tip. Based on the established models, multiple dispersion anafysis is introduced to isolate ingredients sensitive to particular stages of groove wear from the 3D vibrations, and to quantify their relations. The results are physic~Iy interpreted and show that the method presented in this paper is a feasibfe means for on-line monitoring of groove wear development in automated finish machining.