To estimate the acoustic emission (AE) energy released in diamond turning, a quantitative model, which contains the energy from primary, secondary, tertiary cutting zones and the rubbing zones, is proposed and compared with experimental data. The purpose of this model is to assist in process characterization and monitoring. As part of the model developed here the plowing energy, that is, the energy released in the tertiary zone, is approximated by the forming load in the rolling process where the roller is stationary. This load is theoretically calculated by the upper bound method and used in the estimation. A series of diamond turning tests were conducted to check the validity of the model. It was found that the energy content of the AE signal is close to the theoretical predictions. The spectral analysis of the AE signal in these tests is also carried out. It was noticed that when the diamond tool first touches the workpiece without producing any chip, more high frequency components were observed and this stage was recognized as the rubbing stage. The results further support the previous findings, that is, that abnormal rubbing always increases the mean frequency of the raw AE signal.

Issue Section:
Research Papers
Topics:
Acoustic emissions, Diamond turning, Modeling, Signals, Stress, Cutting, Diamond tools, Emission spectroscopy, Rollers, Spectroscopy, Touch (physiological)
1.
McKeown
P. A.
,
1986
, “
High Precision Manufacturing and the British Economy
,”
Proc. Instn. Mech. Engrs.
, Vol.
300
, No.
76
, pp.
1
–
19
.
2.
Pan, C. S., and Dornfeld, D. A., 1986, “Modeling the Diamond-Turning Process with Acoustic Emission for Monitoring Applications,” Proc. 14th NAMRC, SME, University of Minnesota, Minneapolis, pp. 257–265.
3.
Klaiber, J., Dornfeld, D., and Liu, J. J., 1990, “Acoustic Emission Feedback for Diamond Turning,” Proc. 18th NAMRC, SME, Penn State University, May, pp. 113–119.
4.
Kannatey-Asibu
E.
, and
Dornfeld
D. A.
,
1981
, “
Quantitative Relationships for Acoustic Emission from Orthogonal Metal Cutting
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol.
103
, No.
3
, pp.
330
–
340
.
5.
Dornfeld
D.
,
1992
, “
Application of Acoustic Emission Techniques in Manufacturing
,”
NDT&E International
, Vol.
25
, No.
6
, pp.
259
–
262
.
6.
Rangwala
S.
, and
Dornfeld
D.
,
1991
, “
A Study of Acoustic Emission Generated during Orthogonal Metal Cutting—1: Energy Analysis
,”
Int. J. Mech. Sci.
, Vol.
33
, No.
6
, pp.
471
–
487
.
7.
Heiple, C. R., Carpenter, S. H., and Armentrout, D. L., 1991, “Origin of Acoustic Emission Produced during Single Point Machining,” Proc. 4th World Meeting on Acoustic Emission and 1st Int’l Conf. on Acoustic Emission in Manufacturing, S. J. Vahaviolos, ed., ASNT, Columbus, OH, pp. 463–470.
8.
Atkin, R. B., 1987, “Diamond/Aluminum Interactions That Affect Tool Performance,” Ultraprecision Machining and Automation Fabrication of Optics, SPIE, Decker, D., and Jones, R. A., eds., San Diego, Vol. 676, p. 127.
9.
Lin
G. C. I.
, and
Oxley
P. L. B.
,
1972
, “
Mechanics of Oblique Machining: Predicting Chip Geometry and Cutting Forces from Work Material Properties and Cutting Conditions
,”
Proc. Instn. Mech. Engrs.
, Vol.
186
, pp.
813
813
.
10.
Polvani, R. S., Ruff, Jr., A. W., and Whitenton, E. P., 1988, “A Dynamic Microindentation Apparatus for Materials Characterization,” ASTM Testing and Evaluation, Jan., pp. 12–16.
11.
Evans
C.
,
Polvani
R.
,
Portek
M.
, and
Rhorer
R.
,
1987
, “
Some Observations on Tool Sharpness and Sub-Surface Damage in Single Point Diamond Turning
,”
SPIE
, Vol.
802
, pp.
52
–
65
.
12.
Lan
M. S.
, and
Dornfeld
D. A.
,
1986
, “
Acoustic Emission and Machining—Process Analysis and Control
,”
Advanced Manufacturing Processes
, Vol.
1
, No.
1
, pp.
1
–
21
.
13.
Hurt
H. H.
, and
Decker
D. L.
,
1984
, “
Tribological Considerations of the Diamond Single Point Tool
,”
Production Aspects of Single Point Machined Optics, SPIE
, Vol.
508
, pp.
126
–
131
.
14.
Burham
M. W.
,
1976
, “
The Mechanics of Micromachining
,”
Advances in Precision Machining of Optics, SPIE
, Vol.
93
, pp.
38
–
45
.
15.
Ikawa, N., and Shimada, S., 1977, “Cutting Tool for Ultraprecision Machining,” Proc. of the 3rd International Conference on Production Engineering, Kyoto, July, pp. 128–136.
16.
Connolly
R.
, and
Rubenstein
C.
,
1968
, “
The Mechanics of Continuous Chip Formation in Orthogonal Cutting
,”
International J. of Machine Tool Design and Research
, Vol.
8
, pp.
159
–
187
.
17.
Kragleskii, I. V., 1965, Friction and Wear, Chapter 4, Butterworth, pp. 123–167.
18.
Sission
T. R.
, and
Kegg
R. L.
, “
An Explanation of Low Speed Chatter Effects
,”
ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Series B, Vol.
91
, No.
4
, Nov. pp.
951
–
958
.
19.
Drescher
J. D.
, and
Dow
T. A.
,
1990
, “
Tool Force Model Development for Diamond Turning
,”
Precision Engineering
, Vol.
12
, No.
1
, pp.
29
–
35
.
This content is only available via PDF.
Copyright © 1996
 by The American Society of Mechanical Engineers
You do not currently have access to this content.