| This thesis presents a study of tool condition monitoring in turning using optical sensors. The study focuses on the effect of tool wear on the surface finish and the dimensional inaccuracy of machined workpieces in turning operations. Experiments were conducted to measure the tool wear, the surface finish and the dimensional errors of the machined workpieces under different cutting conditions. Based on the experimental results, new mathematical models of surface finish prediction have been developed as functions of tool wear and cutting conditions, that is, cutting speed, feed rate, and depth of cut. In addition the relationship between tool tip wear and dimensional inaccuracy has been investigated. Finally, optimization models that maximize the material removal rate have been developed. |
