Abstract
As part of an industrial cooperation research project, a smart milling tool with indexable inserts was developed as a cyber-physical system. The aim of the development was to increase reliability and service life with cost savings through a continuous predictive analysis of the milling process. Through a continuous recording of physical parameters, cutting force and temperature of each cutting edge as well as the motion/vibration during the machining process, the wear condition of the indexable inserts can be detected by means of intelligent data evaluation. The recorded data can be stored in the tool and is simultaneously available via Bluetooth to a data evaluation station where they can be accessed by the end user on his smartphone, tablet or the like. After the milling process is trained, the end user receives a push message as soon as the process has reached a critical state or a cutting insert has reached the end of its service life and needs to be replaced or turned.
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