Detection of Cutting Phenomena Using Sensor Fusion

Abstract

This paper presents an investigation of the application of a suite of sensors for simultaneous in-situ measurements of machining processes. While not every individual sensor responds to all machining phenomena, the suite of sensors together responds to many machining phenomena of interest, including chip segmentation, chip breakage, and vibrations. The simultaneous use of a suite of sensors with modest data-acquisition equipment and the use of careful preliminary laboratory testing for optimizing sensor performance distinguishes this present proof-of-concept work from prior process monitoring efforts using individual sensors. This paper includes a discussion of pre-deployment laboratory measurements and a full description of the instrumented tool holder, associated circuitry, and data analysis methods. The deployment of multiple sensors of varying sophistication and cost lays a technical foundation for the ultimate objective of industrially practical measurement and monitoring systems for metal cutting processes.