The development of an end-milling process depth of cut monitoring system

Efforts to manage end-milling cutter-tool life depend upon the accuracy of the information used in the assessment of the work done. This presents a problem in many instances because the measurement of cutting-related parameters is difficult, especially when the operations being undertaken do not form part of a repeated manufacturing cycle. This paper presents a methodology utilising ultrasonic sensors for the real-time monitoring of the depth of cut arising during end-milling operations. The paper outlines the architecture of a tool condition monitoring system based upon state of the art microcontrollers. It then considers how depth of cut information can be integrated into such a system in order to support effective end-mill tool-life management functions.

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