A new approach to cutting state monitoring in end-mill machining

A new cutting state monitoring approach is proposed for the real-time predicting of the machining trouble and the surface quality of the machined products. In this approach, the relationships among the mechanical model of cutting process and its corresponding time series model, the surface roughness of the machined workpiece are evaluated through theoretical analysis and experimental investigation. It is therefore revealed that there is the linear relationships among the AR parameter a₁, the stiffness k₃ of cutting model and surface roughness P_z, and consequently the cutting process state can be estimated by only monitoring time series parameter a₁ of vibration signal measured during machining operation. In particular, it was found that the variation in the surface roughness of P_z=3–5 μm can be fully monitored.