Abstract

This paper presents an experimental investigation aimed at identifying and isolating effects of cutting conditions on cutting forces and vibrations from those arising as a result of cutting tool wear. Machining test cuts were conducted using sharp and worn inserts and the effects of cutting conditions (depth of cut, cutting speed and feed rate) studied. Signals were recorded with significant variation of the cutting conditions when the tool was relatively fresh/sharp and/or old/worn such that only the effects of cutting conditions alteration were pronounced on the signals. Time and frequency domain was used to pinpoint the exact nature of changes on the signals due to alteration of the cutting conditions. The depth of cut and feed rate where deemed to affect the signal characteristics significantly and a specific frequency band most sensitive to the changes identified.