Correlation Analysis of Vibration Signal Frequency with Tool Wear During the Milling Process on Martensitic Stainless Steel Material

Martensitic AISI 420 stainless steel is favored for hardness and strength due to the hard phase of martensite and chromium carbide. However, machining this martensitic steel is difficult since the heat conductivity of this material is poor, which can cause an increase in temperature in the machining zone, resulting in a high amount of tool wear and poor machinability of the work material. Therefore, this paper proposes an experiment to monitor end mill tool wear while cutting MSS AISI 420 through cutting frequency analysis, focusing on IPFs and their associated sidebands. This study investigates the correlation between vibration signal frequencies and tool wear during the milling process on martensitic stainless steel (AISI 420) using the Pearson correlation method. The research yields insights into this relationship, with significant implications for tool wear monitoring. Findings revealed a variety of different correlations between vibration frequencies and tool wear progression, including the emergence of the natural frequency as a dominant indicator of severe wear or damage, strong correlations between sideband signals and tool wear through high-frequency sampling, and optimal sensor placement along the Y-axis with the spindle area as a secondary location.