Cutting tools reliability and residual life prediction from degradation indicators in turning process

In the field of cutting tool reliability, an investigation based on four complementary approaches for tool wear assessment is proposed: the approach 1 is a general failure times approach (statistical reliability based on flank wear threshold hitting times), the approach 2 is based on power consumption monitoring (statistical reliability based on power threshold hitting times), the approach 3 is based on vibration signal analysis (statistical reliability based on vibration threshold hitting times), and the approach 4 is based on the evolution of flank wear for each insert (statistical reliability based on predicted failure times). For this study, 30 identical inserts from a same batch were studied with a CNC lathe in identical turning conditions. As the remaining useful life assessment is the final goal, this study highlight four approaches in order to find out the safest one. The results obtained showed that the approach 1 has too many uncertainties, whereas the approach 2 provides more specific and safer replacement times. The approach 3, in the first hand, highlights the fact that cutting conditions are not exactly identical and, in the second hand, leads to a safe conditional replacement of an insert. Finally, it appeared that the approach 4 allows applying a predictive maintenance strategy.