Innovative signal processing for cutting force based chip form prediction K. Jemielniak a , R. Teti b , J. Kossakowska a , T. Segreto b a Institute of Manufacturing Technology, Warsaw University of Technology, Narbutta 86, Warsaw, Poland b Dept. of Materials & Production Engineering, University of Naples Federico II, P.le Tecchio 80, Naples, Italy Abstract This paper reports on the activities of a joint research project work carried out by two Laboratories at the Warsaw University of Technology, Poland, and the University of Naples Federico II, Italy. The joint research work comprised the following main activities: (a) generation, detection, and storage of cutting force sensor signals obtained during sensor-based monitoring of machining processes with variable cutting conditions generating different chip forms, and (b) cutting force signal (CFS) characterization and feature extraction through advanced processing methodologies, aimed at comparing chip form monitoring results achieved on the basis of innovative signal analysis and processing. Keywords: Chip form monitoring, Cutting force sensor, Advanced signal processing 1. Introduction In this paper, the main activities of a collaborative research on chip form sensor monitoring based on cutting force signal analysis carried out jointly by two Laboratories, K. Jemielniak’s Lab at Warsaw University of Technology (WUT) and R. Teti’s Lab at the University of Naples Federico II (UN), Italy, are presented. These activities consist of: (i) generation, detection, storage of cutting force signals (CFS) obtained during sensor-based monitoring of machining processes with variable cutting conditions yielding different chip forms; (ii) examination and characterization of the CFS specimens with the aim of comparing chip form monitoring results achieved with diverse advanced signal processing and analysis methodologies. The WUT volunteered in providing CFS specimens from turning tests under variable cutting conditions, using commercial instrumentation for cutting force detection and storage. The CFS specimens were utilized by the WUT and UN Labs to perform investigations through advanced analysis procedures for CFS processing, characterization and feature extraction to achieve reliable chip form identification and monitoring. This paper reports the characteristics of the CFS specimens and the investigation results obtained by the cooperating Labs, and presents the capabilities of the different advanced signal processing and data analysis methods for chip form prediction. 2. Experimental procedure Cutting tests were performed at the WUT Lab through longitudinal turning of C45 (AISI 1045) steel with coated carbide inserts and variable cutting parameters, yielding different chip forms: - cutting speed = 150, 250 m/min - feed rate = 0.08, 0.13, 0.20, 0.30 mm/rev - depth of cut = 1.0, 1.5, 2.0, 3.0 mm