Abstract
Abstract A complex, but low cost, system for cutting tool monitoring is described in the paper. The device was realized on a single printed circuit board and can additionally be installed on machine tools, without any changes in machine tool construction. The tool condition monitoring system fulfils three basic tasks that comlement each other. Geometric checking is aimed at examining the proper state of tool edges before or after cutting operations. The device uses inductive proximity switches, which are also suitable for measuring rotating tools like milling heads. The most important function is on-line tool condition monitoring. In case of tool failure, machining has to be interrupted as quickly as possible, otherwise the workpiece or the machine tool can be damaged. The system discussed, monitors the cutting load by watching the spindle motor current. The sensed value of the motor current is compared to the load level permitted under the current cutting conditions. The tool wear monitor, which is the third function, records the wear degree of every tool. When a tool has reached the end-of-life state, the system sends a warning signal and initiates the CNC for changing the tool. The structure of the monitoring system is modular, in this way the single functions can be installed separately. However, higher efficiency is obtained when all the three functions are used.
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