Real-time monitoring of flank wear behavior of ceramic cutting tool in turning hardened steels

Flank wear of an alumina-based ceramic cutting tool was determined in hard turning two workpieces (AISI 4340 and 52100 hardened steels) at three cutting speeds (142, 181, and 264 m/min) to devise a real-time monitoring system. Results of the six turning tests were assessed using Kruskal-Wallis test, regression models, and linear trend analysis. Multiple non-linear regression models that explained variation in flank wear as a function of time (second) had a range of R(adj)(2) values of 27.7% for the test 4340-142 to 95% for the test 52100-181. Linear trend models revealed that the highest flank wear rate of the ceramic cutting tool belonged to the test 52100-181. Interaction effect of the three cutting speeds and the two workpiece types was determined to account for 82.2% of variation in flank wear (P < 0.001). The real-time monitoring system designed in this study appeared to be promising in terms of determining and quantifying flank wear behavior of the ceramic cutting tool and optimal hard turning conditions.