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Monitoring Initial Tool Damage of PcBN tools during Hard Milling of Vanadis 4E using Acoustic Emission

Sridhar, Gautam LU ; Persson, Jonatan LU ; Sandsten, Maria LU ; Pozuelo, Sandra Gordon LU and Gutnichenko, Oleksandr LU (2026) 10th Conference on High Performance Cutting, CIRP-HPC 2026 141. p.370-375
Abstract

Tool Coating is a method for enhancing cutting efficiency and extending tool life, essential for machining hard materials. While Polycrystalline Cubic Boron Nitride (PcBN) tools are already well-suited for harsh machining conditions, their durability can be further improved with coatings. However, as the machining operation continues, tool coating loss occurs, reducing the durability of the tool and leading to further, more significant damage. Extensive research has been carried out for significant tool damage like flank wear or crater wear; however, early-stage tool damage is still relatively under-researched. This study proposes a method for real-time detection of initial tool damage during milling using an Acoustic Emission sensor... (More)

Tool Coating is a method for enhancing cutting efficiency and extending tool life, essential for machining hard materials. While Polycrystalline Cubic Boron Nitride (PcBN) tools are already well-suited for harsh machining conditions, their durability can be further improved with coatings. However, as the machining operation continues, tool coating loss occurs, reducing the durability of the tool and leading to further, more significant damage. Extensive research has been carried out for significant tool damage like flank wear or crater wear; however, early-stage tool damage is still relatively under-researched. This study proposes a method for real-time detection of initial tool damage during milling using an Acoustic Emission sensor whose high sensitivity makes it especially suitable for detecting minor changes to the milling process. The proposed method is based on Dynamic Time Warping (DTW), a technique that has been shown to be extremely powerful for analyzing time-series data, yet its application to acoustic emission signals remains underexplored. As verification, accelerometer data from the same experiments were analyzed and compared to the acoustic emission results. The findings suggest that the proposed approach enables the Effective monitoring of early tool degradation, providing a method for predictive maintenance and improving tool life management.

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Please use this url to cite or link to this publication:
author
; ; ; and
organization
publishing date
type
Chapter in Book/Report/Conference proceeding
publication status
published
subject
keywords
Acoustic Emission, DTW, Initial Tool Damage, Milling, Signal Processing, Vanadis 4E
host publication
Procedia CIRP
volume
141
pages
6 pages
conference name
10th Conference on High Performance Cutting, CIRP-HPC 2026
conference location
Cluny, France
conference dates
2026-06-17 - 2026-06-19
external identifiers
  • scopus:105042614551
DOI
10.1016/j.procir.2026.03.054
language
English
LU publication?
yes
id
52a3b289-b7a6-4898-9681-0e333099d020
date added to LUP
2026-09-18 14:21:04
date last changed
2026-09-18 14:21:10
@inproceedings{52a3b289-b7a6-4898-9681-0e333099d020,
  abstract     = {{<p>Tool Coating is a method for enhancing cutting efficiency and extending tool life, essential for machining hard materials. While Polycrystalline Cubic Boron Nitride (PcBN) tools are already well-suited for harsh machining conditions, their durability can be further improved with coatings. However, as the machining operation continues, tool coating loss occurs, reducing the durability of the tool and leading to further, more significant damage. Extensive research has been carried out for significant tool damage like flank wear or crater wear; however, early-stage tool damage is still relatively under-researched. This study proposes a method for real-time detection of initial tool damage during milling using an Acoustic Emission sensor whose high sensitivity makes it especially suitable for detecting minor changes to the milling process. The proposed method is based on Dynamic Time Warping (DTW), a technique that has been shown to be extremely powerful for analyzing time-series data, yet its application to acoustic emission signals remains underexplored. As verification, accelerometer data from the same experiments were analyzed and compared to the acoustic emission results. The findings suggest that the proposed approach enables the Effective monitoring of early tool degradation, providing a method for predictive maintenance and improving tool life management.</p>}},
  author       = {{Sridhar, Gautam and Persson, Jonatan and Sandsten, Maria and Pozuelo, Sandra Gordon and Gutnichenko, Oleksandr}},
  booktitle    = {{Procedia CIRP}},
  keywords     = {{Acoustic Emission; DTW; Initial Tool Damage; Milling; Signal Processing; Vanadis 4E}},
  language     = {{eng}},
  pages        = {{370--375}},
  title        = {{Monitoring Initial Tool Damage of PcBN tools during Hard Milling of Vanadis 4E using Acoustic Emission}},
  url          = {{http://dx.doi.org/10.1016/j.procir.2026.03.054}},
  doi          = {{10.1016/j.procir.2026.03.054}},
  volume       = {{141}},
  year         = {{2026}},
}