Use of model-based cutting simulation system for tool breakage monitoring in milling

Abstract In order to increase productivity in milling operations, a new model-based cutting simulation system for tool breakage monitoring is presented in this paper. The milling process is simulated by a geometrical modelling system in a CAD/CAM work station which can continuously estimate the axial and the radial depths of cut along the NC tool path under varying cutting conditions. Then, the cutting parameters are transmitted to a mechanistic model for the calculation of the dynamic milling force. The dynamic cutting force is further processed to establish a threshold value for tool breakage monitoring. If the measured cutting force exceeds the threshold value and the specific tool breakage feature appears, the occurrence of tool breakage will be assumed and therefore an automatic tool exchange action will be taken. Finally, experimental results have been provided to prove the feasibility of this proposed monitoring method.