Detecting tool breakage in turning aisi 1050 steel using coated and uncoated cutting tools

When a tool wears or breaks, cutting forces increase slightly right after the tool breakage and then decrease sharply. The change of cutting forces can itself be a good indicator to detect the tool failure. The experimental set-up developed in this research consists of a dynamometer, a pre-amplifier, an A/D converter, and a personal computer. The workpiece material is AISI 1050 steel and the tool material is coated and uncoated tungsten carbide (ISO P25). The type of insert that is used is DNMG 150608. No cutting fluid was used during the turning operations. The performance of the system has been tested experimentally for certain machining conditions and the experimental results showed that the system was being successful in tool breakage detection.