Relationship between Vibration Signals and Tool Wear in Milling Process

Vibration is among the common tool parameters used in tool condition monitoring (TCM). TCM plays a crucial role in the control and management of processes. There is an increased need to produce machines that are more efficient and that incur minimum maintenance costs. Tool failure and wear greatly reduce the cost while constantly maintaining the quality of production. Various monitoring systems have been developed by past researchers aimed at better configurability and flexibility. In this work, a simple and reliable method for data transmission in rotating machines using a slip ring system was applied and tested. Previous data transmission systems involve the use of telemetry and rotary transformers, which are big in size and require complex wiring systems. During the testing, the vibrations at the tool tip were measured using an accelerometer. The results showed that the vibrations increased with an increase in the tool wear. However, in relation to several cutting parameters, the vibrations increased when the feed rate was high but decreased when a lower value of the axial depth of cut, a, was used.