Tool breakage monitoring based on the feature fusion of spindle acceleration signal

Tool breakage is a prominent concern during the rough machining process, which is essential to be monitored online to prevent this phenomenon and maintain the surface quality. In this study, a tool breakage monitoring method is proposed based on the mechanism model and machining data using the acceleration signal. This method takes care of the whole process with the transition from a fresh tool to its full breakage. The mechanism of the tool breakage is obtained by this method, which is then implemented into a single synthesis parameter based on the frequency domain feature for the analysis of tool condition, and the data of fused features are statistically processed to carry out the breakage monitoring. The parameter 3 σ¯ (three times the mean of standard deviation) is taken as the threshold value to determine the breakage condition in real time. The experimental results are in good agreement with the theoretical model, which proves the efficiency and simplicity of online tool breakage monitoring based on the proposed method.