A low cost wireless high bandwidth transmitter for sensor-integrated metal cutting tools and process monitoring

A transmitter system has been developed to collect high bandwidth data from sensor integrated cutting tools. The system collects high resolution end milling data during cutting without interfering with the machining process. A Bluetooth transmitter and instrumentation amplifiers are integrated into an end milling tool holder. The system is designed to power and sample a variety of sensors residing inside the tooling. The compliance of the tooling is unaffected by the sensing system. A tool integrated with a torque sensor is demonstrated. The cutting torque signal is compared to theory and experimental tests with a traditional bed type dynamometer.