Tool wear inspection of polycrystalline cubic boron nitride inserts

In industry, highly frequent inspection of tooling used to machine safety critical components is common place. Worn or damaged tools produce undesirable surface finishes leading often to early failure of the part due to fatigue crack growth. In the development stages of polycrystalline boron nitride tools, the tool wear inspection technique is an off-line run-to-failure method. This approach interrupts the cutting process intermittently, to measure the tool wear using optical and scanning microscopy. This method is time consuming and expensive, causing bottlenecks in production. The overall aim in industry is to develop an on-line, automated system capable of informing the operator of the tool’s imminent failure. This paper focuses on treating this process as a preventative maintenance problem by studying whether acoustic emission can be used as an indirect measurement of tool wear at any given time. Acoustic emission measurements taken from the machining process of face turning are investigated here. Basic analysis in the frequency domain using principle component analysis reveals a number of interesting insights into the process. Relationships between the sharpness of the tool and the magnitude of the frequencies suggests promising link between acoustic emission and tool wear.