TOOL CONDITION MONITORING IN MICRO-MILLING OF BRITTLE MATERIALS USING MULTISCALE SENSORS
Keywords:
Micro-Milling, brittle materials, tool wear, wavelet, tool condition monitoringAbstract
The ability to fabricate 3-D features cost effectively on a wide range of materials has necessitated so much interest in micro milling operations. Despite its successes in the machining of miniature parts and complex shapes with high accuracy, micro machining still encounters problems such as tool wear, cracks, chatter, vibration, and tool stress, thereby causing tool breakage. This research is aimed at developing a robust approach for monitoring tool wear by employing Tool Monitoring Condition (TCM). Attention is focused on the performance of slot milling experiments on brittle materials (glass and silicon) using solid tungsten carbide end cutting tools. Raw experimental data are acquired from AE and force sensors. The signals are processed using Wavelet decomposition techniques. Features are extracted and selected from this decomposition and these features were further used to train and develop an effective TCM solution.