Investigation of progressive tool wear for determining of optimized machining parameters in turning

•Presents a statistical approach for investigation of progressive tool wear.•The effect of cutting parameters on tool wear were analyzed with ANOVA.•AE sensor and dynamometer were evaluated for detection of tool breakage.•Taguchi based prediction was compared with experimental results.•Optimization of machining parameters during turning were obtained. On-line monitoring of tool wear and tool breakage are very important to reduce production costs through the optimization of machining parameters. Increasing cutting forces affect workpiece quality and tool condition that is the ultimate aim of production line and progressive tool wear which can trigger the tool breakage. Taguchi method is extensively used for determining number of experiment while variance analysis (ANOVA) deals with which parameter/s is/are effective on output. This study contains experiments and optimization processes during turning of AISI 1050 material with 3 input parameters (cutting speed, feed rate, tool tip) using Taguchi method. In order to determine the condition of the cutting tool, measurement of tangential cutting force and acoustic emission (AE) were carried out during metal removing. ANOVA results showed that cutting speed is the most effective about %45 and tool tip is the second about %35 on tool wear. On the other hand, the effect of feed rate on tangential cutting force (%88) and cutting speed on AE (%80) is remarkably higher than the other two parameters. In order to obtain the minimum tool wear value, the optimum cutting parameters have been selected as v1 = 135 m/min, f2 = 0,214 mm/rev, T2 = P25. By implemented sensor system tool breakage can be successfully detected and used for producing high quality materials with low costs.