A study of noise emission for tool failure prediction

Abstract

The relationship between noise emission and tool wear for tungsten carbide P30 and HSS tools and AISI 1045 and AISI 4340 steels are investigated. Results show that a characteristic frequency of around 4-6 kHz exists for a wide range of tool-workpiece materials and cutting conditions. The sound pressure level at the characteristic frequency is distinctly higher than machine and background noise for tungsten carbide tools and shows a good correlation with the flank wear. The noise level falls just before the tertiary wear zone and provides a tremendous potential for tool failure prediction. © 1986.