Akustisk emission vid skärande bearbetning från den adhesiva mekanismen som funktion av förslitningsutvecklingen

The adhesive mechanism is one of the most significant degradation processes of the edge in metal cutting. Although knowledge about adhesion and edge buildup (BUE) has increased in recent years, there are still areas that are less explored. The adhesion has a regularity in the form of clusters: In a cluster, the chips vibrates with a certain frequency. The frequency varies with several influencing factors. In this thesis, a possible connection between acoustic signals and wear of the cutting edge is researched. Audio signals from cutting edges with varied wear must be analyzed. To investigate the adhesive mechanism, the machining process turning will be used. The cutting edge is analyzed optically with a microscope. According to previous research, the adhesive wear has been shown to be mostly dependent on the cutting speed. The size of the stagnation zone depends largely on the friction angle and the shear plane angle, where the friction angle changes depending on the rake angle and the shear plane angle changes depending on the cutting speed. Adhesion wear has been shown to be a fatigue process. This thesis aims to investigate the development of the adhesive mechanism towards the wear status of the tool. The end goal is to construct a model that explains what happens in the wear zones on the edge and to detect changes in the acoustic signal from the cutting zone that occurs during adhesion wear. The cutting zone sound from two cutting tools with different cutting times is used in Fourier analysis. Insert number two will be worked until chipping occurs and examined optically with a microscope between each cycle to verify if chipping was present. One chip was examined after each cycle under a microscope to see if residues from the insert got stuck on the chips. Cycle number one with insert number one (new edge) shows no clear adhesive mechanism while cycle number one with insert number two shows a clear adhesive mechanism. The same cutting speed is achieved during cycle number five and number 18 with cutting tool number two. The frequency increases 11% and the amplitude decreases 42% from cycle number 5 to cycle number 18. Chipping occurred in cutting tool number two after 25 cycles. The frequency of the adhesive mechanism increases, and the amplitude decreases when the insert wears. A reasonable hypothesis is that the surface that is welded together becomes larger with increased wear: The spring in the adhesive system becomes stronger while the mass remains constant. A hypothesis that the amplitude of the adhesive mechanism is low during cycle number one with insert number one may be due to the fact that the workpiece used was at room temperature. No significant degeneration has occurred of the chip surface