In this study, we developed a novel wireless compact acceleration sensor that can continuously monitor acceleration for a long duration at a machining site to monitor the vibration acceleration of a lathe turret. We examined a method of diagnosing machining conditions of a lathe that uses various tools automatically exchanged on the turret by simultaneously monitoring the vibration acceleration in combination with CNC servo data. We measured the vibration acceleration of a lathe turret and obtained servo motor load and coordinate value information to validate the potential for predicting cutting tool wear. Furthermore, we demonstrated the effectiveness of the wireless compact acceleration sensor for tool management.

Diamond abrasive grains are used as tools for machining hard and brittle materials because of their excellent hardness and abrasion resistance. Metal bond, electrodeposition, resin bond, and vitrified bond are the major abrasive grain fixing methods for general diamond tools. In this study, diamond abrasive grains were ejected on the surface of titanium alloy, and directly fixed by laser irradiation. Processing of soda glass, sapphire, and zirconia ceramics was performed using the developed milling tool. The applicability in industrial and medical fields is discussed.