A new algorithm for the detection of tool breakage in milling

In this paper a novel signal processing algorithm is presented for the detection of tool breakage using the displacement signal (RORPA). The algorithm extracts information from consecutive revolutions to decrease dependencies on runout conditions and idle noise, creating a much more robust signal for the automatic determination of tool breakage conditions. The algorithm is explained as well as the determination of dynamic thresholds. The thresholds are set using the information regarding the cutting conditions (mean displacement signal and its slope during transient milling). Examples with real data are also presented. A critique of the overall performance and future work incorporating information from x and y channels completes the discussion.