Prediction models for on-line cutting tool and machined surface condition monitoring during hard turning considering vibration signal

Turning of hardened steel is an immense issue of interest concerning with machining technology and scientific research. A strategy to analyze vibration signals and its correlation on surface roughness and tool wear has not attracted much breakthrough in research so far in hard machining. Therefore, tool condition monitoring (TCM) study will be definitely worthwhile for the effective application in hard part turning. The current study examines about the online prediction of flank wear and surface roughness monitoring during dry hard turning of AISI 52100 steel (55 ± 1 HRC) utilizing MTCVD multilayer coated carbide insert (TiN/TiCN/Al 2 O 3 ) considering machining parameters and vibration signals through development of prediction model (MLR and MQR) after studying the Pearson correlation coefficient and test for its accuracy. Pearson correlation coefficient for feed on flank wear is utmost pursued by acceleration amplitude of vibration ( Vy ) in radial direction, depth of cut and cutting speed. Similarly, acceleration amplitude of vibration followed by cutting speed and feed has strong correlation with surface roughness. MQR model predicts well for responses as percentage of error is quite less and cutting speed is obtained to be the most important parameter for vibration signal. Multiple quadratic regression (MQR) models are observed to be noteworthy, effective and adequate to predict response outputs with regards to the combined effect of machining parameters and vibration signals online. A corrective measure can safely be taken with reasonable degree of accuracy during hard turning.