An approach for on-line cutting edge stress estimation

Cutting edge deteriorations are attributed to higher mechanical and thermal stresses working on it during metal cutting. However, the stress estimation is a difficult task, especially when on-line estimation is desired. This paper presents a new approach for cutting edge mechanical stress estimation and load simulation. The approach can be applied in the implementation of on-line stress estimation to the study of stress state at the cutting edge and the strategy of real-time edge deterioration monitoring. The approach is based upon cutting force measurement and cutting edge load analysis. The concept of load function and related stress are introduced to estimate stresses working on the cutting edge. With multiple regression, the related stresses can be estimated on-line, from which the actual stresses can be estimated. The method for two-dimensional stress estimation of a cutting edge is illustrated and the principle can also be applied to three-dimensional stress estimation of a cutting edge. The experimental results, obtained with a developed real-time monitoring system and their analysis with respect to cutting edge stress estimation and analysis under different processing phenomena are also reported.