Modeling of Sound Generation Mechanism During the Turning Process

Tool wear has a significant influence on the turning process. Investigations on tool wear monitoring through various methods and sensors have been widely conducted to determine and predict the tool wear. In this study sound generation mechanisms during turning process have been investigated comprehensively and three sound generation sources have been determined and distinguished. Sound generation mechanisms which originated from tool vibration, deformation in the workpiece and vibration at the contact zones (friction), have been investigated and frequency range of the sound generated through each mechanism has been determined. It has been shown that these mechanisms produce sound in 10s hertz, kilohertz and megahertz respectively. Then the mechanism which is appropriate for tool condition monitoring has been studied and suggested. Then the relation between the sound generation mechanisms and chip formation has been studied during machining. Hence, a deep understanding about the machining process has been brought out. Findings could lead to an effective approach to monitoring the machining process, not only using mathematical signal processing methods, but also through a physical comprehension background. Experimental studies have been conducted to evaluate developed theories and models. Experimental results have shown effectiveness of the proposed approach.