An overview of approaches to end milling tool monitoring

• Published in: International journal of machine tools & manufacture 1999, Vol.39 (1), p.105-122
• Main Authors: Prickett, P.W, Johns, C
• Format: Article
• Language: English
• Subjects: Applied sciences; Condition monitoring; Cutting process; Exact sciences and technology; Industrial applications; Industrial metrology. Testing; Mechanical engineering. Machine design; Milling; Milling (machining); Monitoring; Process control; Sensors; Tool breakage; Wear of materials
• ISSN: 0890-6955; 1879-2170
• DOI: 10.1016/S0890-6955(98)00020-0

The increase in awareness regarding the need to optimise manufacturing process efficiency has led to a great deal of research aimed at machine tool condition monitoring. This paper considers the application of condition monitoring techniques to the detection of cutting tool wear and breakage during the milling process. Established approaches to the problem are considered and their application to the next generation of monitoring systems is discussed. Two approaches are identified as being key to the industrial application of operational tool monitoring systems. Multiple sensor systems, which use a wide range of sensors with an increasing level of intelligence, are seen as providing long-term benefits, particularly in the field of tool wear monitoring. Such systems are being developed by a number of researchers in this area. The second approach integrates the control signals used by the machine controller into a process monitoring system which is capable of detecting tool breakage. Initial findings mainly under laboratory conditions, indicate that both these approaches can be of major benefit. It is finally argued that a combination of these approaches will ultimately lead to robust systems which can operate in an industrial environment.