Abstract
This study focuses on the detection of rotating cutting tool failure and proposes a method using an acoustic emission (AE) sensor to detect chipping of the cutting edge on the end-mill cutter and cutting tool breakage of the twist drilling cutter. In order to detect the AE signal from the rotating cutting tool, the AE sensor is coupled with the cutting fluid supply system and the cutting fluid is used as the medium which transmits the AE signal. This sensor system was designed through a series of frequency response measurements of the AE signal in fluid flow. In the frequency characteristics of the AE signal when the chipped tool is used, characteristic peaks are observed at the frequency which is associated with the rotational frequency of the spindle and its harmonic frequency. Using this phenomenon, a practical algorithm for detecting cutting edge chipping has been developed. A practical method is also proposed to detect twist drill breakage.
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