Tool Condition Monitoring Method Assisted by Real-time Cutting Force Simulation for End Milling Operation

Abstract

The purpose of this study is to propose a practical tool condition monitoring method in end milling operation. In the proposed method, real-time cutting force simulation is performed in parallel with actual milling operation. The tool condition is recognized by comparing the spindle motor torque, which can be monitored through CNC without additional sensors, with the predicted cutting torque. This method is practical because the parameter required for real-time cutting force simulation can be immediately and automatically identified at the beginning of the milling operation, and it requires no additional sensor installation. The effectiveness of this method was confirmed by the experimental verifications.