The development of an on-line milling cutter tooth breakage detection system

Abstract

This paper reports the development of an on-line milling cutter tooth breakage detection system. The method is based upon the utilization of existing machine tool controller signals as a means of monitoring the milling cutting process. An approach to the design and development of a low-cost but robust tooth breakage detection system is described. The developed system is tested under a number of carefully controlled cutting conditions. The successful identification of tooth breakage is confirmed in each case. Further tests are then considered in order to demonstrate the robustness of the approach used under what could be termed as ‘normal’ machining operations, such as break-in and break-out machining and shoulder milling. The deployed method is seen to operate effectively under these conditions. The final stage of this work considers the further development of this approach into a fully operational system. It is proposed that effective low-cost tooth breakage systems can be developed and made available to machine tool manufacturers for inclusion within their machine tool controllers.