EXPERIMENTAL SET-UP AND PROCEDURES

In the figure 5 we can see the experimental set-up. The turning test were carried out on a turret lathe of
380 mm swing. The work pieces were chuck-mounted and supported by a running center. The cutting
force was monitored by strain gauges attached to the tool holder and calibrated. The acoustic emission
signals were sample and processed by the AE instrument system. Figure 6. show the schematic diagram
of the AE instrument system. The AE instrument system consisted of an AE piezo-electric transducer, a
pre-amplifier with pass filter, a main amplifier , a high speed A/D(Analog to digital converter)
converter and a personal computer.

Fig. 5

Fig. 6
The first set of experiments consisted of varying the depth of cut, the
cutting speed, the feed rate and the nose radius. During these
experiments, it was necessary to control tool wear because it has an
influence on the surface roughness and onset of chatter. In the second set
of experiments, the above parameters were kept constant and turning was
continued until tool war was high enough to cause chatter.
 RESUTLS AND DISCUSSION

Effect of cutting conditions on acoustic emission

The following results were obtained from a series of preliminary test prior to the proper turning test:
i. There is very Little decrease of the amplitude of the sanded signals with increase in the distance
from the cutting edge along the shank of the tool holder. For this reason the sensor was mounted al
a considerable chips from the cutting edge.
ii. High frequency components were observed not to correlate well with intensity of cutting
conditions. The frequency spectra were calculated by Fast Fourier Transform algorithm, witch is
the often used in AE signal processing.
iii. High power components existed between 100 and 500 kHz. Therefore, an analysis done in this
band would remove or minimize the effects of the insensitivity of AE parameters on cutting
conditions. The maximum sensitivity of the sensor used was at 350 kHz as stipulated by the
manufactures.