A Study of the Contact Interface of a T-slot Milling Cutter Using an Ultrasonic Method

Abstract

As there is no reliable mathematical model to analyze a simultaneous multi-point contact, ultrasound offers an effective way to study the contact between two objects. In this study, a measurement of the contact area between a T-slot milling cutter and a steel plate was investigated by using ultrasonic regional detection. A single transducer was equipped to inspect the contact surface. The transducer movement was 0.15 mm, which resulted in 25,600 scanning data points within a 24 mm × 24 mm square area. The scanned readings were taken from the original signal and then processed to plot the contact patches, using MATLAB. The image of contact area between a T-slot milling cutter and specimen can be worked out using image analysis software. The range of contact areas varies from 3 mm² to 49 mm² in axial contact and from 0.3 mm² to 9.6 mm² in lateral contact, depending on the contact force and the definition of contrast ratio. Knowing the size of contact area is helpful for conducting a wear diagnosis. In addition, a distribution map of contact pressure against the applied loading is presented.

Keywords:

• contact area
• ultrasonic application
• wear diagnosism