A microcontroller-based end milling cutter monitoring and management system

The monitoring of end milling cutting operations for tool breakage is achieved using a low-cost microcontroller-based system. The system is based upon acquiring and analysing machine tool-based signals for characteristic responses to tool breakage. Spindle speed and load signals are shown to be responsive to tool condition and thus capable of supporting the deployed approach. The resulting system operates in real time with tool breakage detection consistently diagnosed within two revolutions. The monitoring function is extended to consider tool wear using analysis methods applied in the time and frequency domains. Decisions about tool condition are made by integrating all relevant information into a rule base. Higher-level tool management functions supported by the deployed system are identified.