Early prediction of impending end-milling tool failure using acceleration signals

A technique capable of monitoring an end-milling tool using acceleration signals is developed based on the Data Dependent Systems methodology. The technique does not require spindle encoding, tooth pass correlations, or other means of relating the sampling frequency to the machining frequencies. The energy modes of the first and second multiples of the tooth pass frequency are shown to be sensitive to the minute changes that occur as the tool wears and approaches failure. The abilities of the technique are demonstrated using three end-milling life tests. Early warning of impending failure is provided in all three of the life tests. Society of Manufacturing Engineers 1998