Relation between tool wear and workpiece modal vibration in ultra-precision raster fly cutting

Tool wear is a key factor affecting machined surface quality; numerous methods have been adopted to reflect tool wear features online. In the present research, workpiece modal frequencies were employed to present tool wear level in ultra-precision raster fly cutting (UPRFC) process. In time domain, cutting force composition and the relation between cutting force amplitude and tool wear level were explored. In frequency domain, the relation between workpiece modal frequencies as a response of cutting force stimulus and tool wear level was investigated. Theoretical and experimental results reveal that the peak power spectrum density (PSD) values of the workpiece modal vibration (especially the first order workpiece modal vibration) grow with the progress of tool wear, the width of flank wear land and the first order workpiece modal vibration has a linear relationship, which could be used to predict tool wear in UPRFC and even other intermittent cutting process.