Abstract
This paper presents real-time tool breakage detection by sensor fusion concept of an acoustic emission sensor and a built-in force sensor in turning and drilling processes. Miniature piezoelectric force sensors were inserted in the tool turret housing of an NC lathe and in an auxiliary mounting plate of a machining center. These built-in sensors are economical and do not disturb machining operations. When a tool breaks, a burst type AE signal is followed by a significant drop of cutting force in turning or thrust force in drilling. The AE burst signal was used to trigger cutting force (thrust force) inspection. The algorithm was implemented on a Digital Signal Processing (DSP) board for real-time tool breakage monitoring. Experimental works showed an excellent real-time monitoring capability of the proposed tool breakage detection system.
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