The Detection of Tool Breakage in Milling Operations

TLDR

The paper proposes a simple, efficient algorithm to detect cutter breakage from milling force signals. The algorithm samples forces synchronized with cutter teeth, averages per tooth to remove basic variation, then uses first and second differences of these averages to detect breakage and differentiate it from sudden cutting condition changes. Simulations and experimental milling tests confirm the algorithm’s effectiveness in detecting cutter breakage.

Abstract

The paper describes a rather simple and efficient algorithm for processing the milling force signal to detect cutter breakage. Using sampling synchronized with cutter teeth the basic variation per tooth is removed by calculating average forces per tooth. The first difference of these forces detects both breakage and some sudden changes in cutting conditions (cornering, milling over a slot). The second difference distinguishes between the two. The algorithm is illustrated by computational simulations as well as by measurements in milling tests.