Multi-purpose sensor for cutting process monitoring and optimisation

Abstract

Systems for monitoring cutting processes increase process reliability and assure a higher rate of quality by detecting interferences such as collisions, breakages, degree of wear or unstable conditions. The aim of the project is to develop algorithms for monitoring milling processes by processing raw data from the acoustic emission sensor in such a way that it is possible to define the degree of tool wear, machine vibration and thus process design by using a single multi-purpose Acoustic Emission (AE) sensor. This requires a suitable sensor for which hardware and software have to be developed. In the first part of the project, an acoustic emission sensor was used to investigate tool wear. The results show that raw data as well as the amplitude maxima can be evaluated with an FFT-analysis to determine the degree of wear.