The Detection of Tool Breakage in Milling Operations

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.