Analytical modeling of acoustic emission for monitoring of peripheral milling process

This paper presents the development of an analytical model relating the acoustic emission (AE) energy content to the cutting process parameters in peripheral milling and the experimental verification of the effects of the cutting parameters on the AE energy measurement to assess the applicability of AE sensing to the monitoring of peripheral milling. The model consists of an oblique cutting component and a rubbing component. It includes the contribution from both the AE attributed to plastic deformation in the primary shear zone and the AE resulting from interfaces between chips and the rake faces of the cutting teeth, between the workpiece and the cutter periphery as well as between the cutter flank and the machined workpiece surface. The adoption of an effective shear angle and a mean friction angle in the model formulation provides insight into the fundamental mechanism of the cutting process responsible for the generation of the acoustic emission. A numerical example following the model development and a series of peripheral milling tests show that the true mean square voltage of the AE signal room peripheral milling increases with the primary cutting parameter (cutter rotating speed, feedrate, axial and radial depths of cut). The result of this work suggests that the energy measurement of the AE signal can be effectively used for the monitoring of peripheral milling processes.