A multi-sensor integrated smart tool holder for cutting process monitoring

As two of the most significant parameters reflecting the cutting process, cutting force, and vibration are often adopted for tool condition monitoring (TCM) which is especially important in modern machining. Hence, various methods and sensors for detecting these two signals have been proposed and developed. In this study, an innovative multi-sensor integrated smart tool holder is designed, constructed, and tested, which is capable of measuring triaxial cutting force, torque, and cutting vibration simultaneously and wirelessly in milling operations. A standard commercial tool holder is firstly modified to integrate six capacitive sensors and an acceleration sensor. All the sensors and other electronics, like data acquisition and transmitting unit, are incorporated into the tool holder as a whole system. The characteristics of the device are then determined by a series of tests. Besides, an effective TCM model is built by fusing the features of cutting force and vibration. Experimental results showed good performance of the proposed system which could support wide and flexible application scenarios.