An investigation of tool-wear monitoring in a high-speed machining process

The monitoring of high-speed machining processes is a key issue for ensuring better use of new machine-tool capabilities. An investigation of tool-wear monitoring in a high-speed machining process on the basis of the analysis of different signals' signatures in the time and frequency domains is presented in this paper. Sensorial information from relevant sensors (i.e., dynamometer, accelerometer and acoustic-emission (AE) sensor) is compared and analyzed, assessing the deviation in representative variables in the time and frequency domains. The time- and frequency-domain analysis confirms the relevance of cutting-force and vibration signals' signatures for tool-wear monitoring in high-speed machining (HSM) processes. Likewise, the spectrum analysis of AE signals corroborates that AE sensors are very sensitive to changes of tool condition, with increasing amplitudes of up to 160 kHz for worn tools. (C) 2004 Elsevier B.V. All rights reserved.