Vibroacoustic signals for optimizing turning modes of CNC machines

The present study aims to justify the possibility of using acoustic signals for correcting turning modes of computer numerical control (CNC) machines. The object of the study is the technological assurance of the required surface roughness during the machining of turned parts. Experimental planning and organization, spectral and correlation analysis, as well as optimization methods were used. Experiments were carried out using a CNC turning machine. St3 and steel 45 grades of structural steel were used for machining. The condition of the cutting insert was assessed using an electronic cutting tool measuring device. Vibrations were recorded using an accelerometer; the obtained vibroacoustic signals were processed using software developed by the authors. Spectral analysis was used to identify the frequency range of the signal that showed the strongest correlation with surface quality (6–12 kHz). The conducted studies resulted in relationships for assessing the surface roughness formed during the finishing of shaft-type parts made of St3 and steel 45 steel grades. Vibroacoustic signals were demonstrated to be appropriate for the correction of turning modes based on cutting insert wear monitoring. Thus, the power of vibration signals in the range from 0.001 to 0.015 dB corresponds to the normal cutting-insert wear zone recommended for operation. If the power exceeds 0.015 dB, a transition to a zone of severe wear is observed, which requires stopping machining due to the high probability of defects. Preliminary testing on a batch of parts showed the possibility of increasing efficiency by 15–20 % without adversely affecting the surface roughness of the machined parts. Thus, vibroacoustic signals recorded by an accelerometer during machining can be used to increase the efficiency of manufacturing turned parts on CNC machines and reduce unexpected cutting-insert failures. 

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