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2nd International Conference on Design, Materials, and Manufacturing IOP Publishing
IOP Conf. Series: Materials Science and Engineering 220 (2017) 012038 doi:10.1088/1757-899X/220/1/012038
1234567890

On-line Monitoring for Cutting Tool Wear Condition Based

on the Parameters

Fenghua Han1*, Feng Xie1

1
School of Electrical Engineering & Automation, Anhui University, Hefei 230601,
China
*E-mail: 1617972207@qq.com

Abstract. In the process of cutting tools, it is very important to monitor the working state of
the tools. On the basis of acceleration signal acquisition under the constant speed, time domain
and frequency domain analysis of relevant indicators monitor the online of tool wear condition.
The analysis results show that the method can effectively judge the tool wear condition in the
process of machining. It has certain application value.

1. Introduction
With the wide use of numerical control machine tools, the modern manufacturing system is
developing towards the direction of the highly automated. The real-time monitoring for the state of
cutting tool is needed. According to the statistics [1], NC machine tools equipped with cutting tool
monitoring system can make its productivity increased by ten percent to sixty percent. The utilization
rate of machine tools are increased by fifty percent, so the real-time monitoring of machine tool is
great significance.
Wang Ming used wavelet theory to extract the vibration signal and analysised the change of the
signal amplitude and frequency vibration to determine the state of tool wear. Gao Weijia put forward a
kind of method based on artificial neural network after blade abrasion value prediction and used the
universal tool microscope to measure the abrasion value.

2. Cutting tool wear monitoring method analysis

The method of cutting tool in machining condition monitoring contains the processing of signal,
analyze signal, extract feature and diagnose wear fault. Generally the cutting tool vibration signal
contains the valid information of the tool wear. The tool wear state is judged by picking up processing
vibration signal from the acceleration sensor and analyzing the relevant indicators[2].

2.1. The time domain analysis

Time domain waveform is usually the most intuitive analysis method. With obvious characteristics of
the wear, the time domain waveform directly correspond to different degree of wear. The vibration
waveforms show the different shapes[3].
Amplitude parameter analysis of indicators are divided into dimensional parameter and the
dimensionless parameter. The dimensional parameters contain the mean, root amplitude, kurtosis, etc.
Dimensionless parameters have waveform, pulse, tolerance index and so on. The following is a
calculation formula of each index:

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Published under licence by IOP Publishing Ltd 1
2nd International Conference on Design, Materials, and Manufacturing IOP Publishing
IOP Conf. Series: Materials Science and Engineering 220 (2017) 012038 doi:10.1088/1757-899X/220/1/012038
1234567890

1 N 1 4 2
 xi / xa  3 （2）,
N 1

 ( xi  x ) （1）, Kurtosis index xq 

1 2
Variance 2 
N i 0 N i 0
N

f
N

f
2
i pi i pi
Power spectral centroid FC  i 1
N （3）,The mean square frequency MSF  i 1
N （4）
p
i 1
i  pi
i 1

The xi for collection of data, xp as the peak, N as the collection data points, fi the power spectrum of
the frequency，pi the power spectrum amplitude.

2.2. The frequency domain analysis

Frequency domain analysis of tool wear monitoring is based on the analysis of time domain waveform.
It is to further find out the vibration internal relations of acquisition signal of normal and wear parts.

3. The design for tool wear experiments

The tool wear test is to use new knife from early state to the late continuous processing. In order to
study the different levels of wear, the wear mechanism of cutter and the influence law of wear, the
different parameters of the time frequency domain are analyzed. The experiment is mainly to collect
the acceleration signals under the constant speed. Acceleration sensors are adsorbed to the tool spindle
lateral X and Y direction. It will be collected on the stability of the dynamic signal by the acceleration
sensors. The signals are transmitted to the acquisition card and imported into the MATLAB software
to analyze in the computer [4].
In order to apply vibration test method in tool wear monitoring, as shown in figure 1 is collected
vibration signals of tool wear monitoring system.
Acceleration
sensor 1
eigenvalue Contrast
DAQ card
extraction judgement
Acceleration
sensor 2
Figure 1. Collection and analysis of vibration signal monitoring figure.
The system consists of milling drilling machine, the acceleration sensor, a four-channel data
acquisition card (NIUSB4431) and PC software MATLAB analyzer. The experiment of specific
machine of ZXJ7016 is the speed regulating pole change motor machine. The cutter material is a
straight shank end mill with two teeth. The sampling frequency is 20000 Hz. The sampling time is 2
seconds and the signal acquisition is taken from the new state to severe wear.

4. Results of data analysis

The spindle speed of 750 r/min, feeding rate of 70 mm/min, turning quantity is 0.5 mm and the
processing thickness is 5 mm.
To contrast the different level tool wear state are based on the analysis of the time domain and
frequency domain parameters. The different parameters have different sensitive of the wear degree. It
is need to select a number of effective parameters as the characteristics of fault diagnosis [5].

2
2nd International Conference on Design, Materials, and Manufacturing IOP Publishing
IOP Conf. Series: Materials Science and Engineering 220 (2017) 012038 doi:10.1088/1757-899X/220/1/012038
1234567890

0.0000E+00 8.0000E-08
Early Metaphase Late
-2.0000E-05 6.0000E-08
-4.0000E-05 4.0000E-08
-6.0000E-05
2.0000E-08
-8.0000E-05
0.0000E+00
-1.0000E-04 Early Metaphase Late
Figure 2. Average line chart Figure 3. Kurtosis line chart
30 40
25
30
20
15 20
10
10
5
0 0
Early Metaphase Late Early Metaphase Late
Figure 4. Impulsion index line chart Figure 5. Tolerance index line chart
From figure 2 to figure 5 in the line chart, the average, kurtosis, impulsion index and tolerance
index is more sensitive indicator of tool wear signals. These can be used as mixed characteristics of
tool wear monitoring.
2.7000E+03 1.5000E+07
2.6500E+03
2.6000E+03 1.0000E+07
2.5500E+03
2.5000E+03
2.4500E+03 5.0000E+06
2.4000E+03
2.3500E+03 0.0000E+00
Early Metaphase Late Early Metaphase Late
Figure 6. Power spectral centroid line chart Figure 7. Mean square frequency
The above two line chart about the frequency domain index, both the mean square frequency and
the power spectral centroid are sensitive to the vibration signal of the tool wear and have better signal
indication. Here are all wear period of time domain and frequency domain spectrum analysis[6].

3
2nd International Conference on Design, Materials, and Manufacturing IOP Publishing
IOP Conf. Series: Materials Science and Engineering 220 (2017) 012038 doi:10.1088/1757-899X/220/1/012038
1234567890

-3
x 10

0.06

2
0.04

1.5
acceleration

0.02

amplitude
0
1

-0.02
0.5

-0.04

0
0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 0 100 200 300 400 500 600
time/s frequency

Figure 8. Early tool wear time domain diagram. Figure 9. Early tool wear frequency domain diagram.
-3
x 10
0.08

0.06 2.5

0.04
2
0.02
acceleration

0
amplitude

1.5
-0.02

-0.04
1
-0.06

-0.08 0.5

-0.1

0
0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 0 100 200 300 400 500 600
time/s frequency

Figure10. Mid tool wear time domain diagram. Figure11. Mid tool wear frequency domain diagram.
-3 -4
x 10 x 10
5
2.5

2 4.5

1.5 4

1 3.5

0.5
acceleration

3
amplitude

0
2.5
-0.5
2
-1
1.5
-1.5
1
-2
0.5
-2.5

0
0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 0 100 200 300 400 500 600
time/s frequency

Figure12. Late tool wear time domain diagram. Figure13. Late tool wear frequency domain diagram.

The vibration signal can get varying degrees of cutting tool wear from the time domain and
frequency domain. Above a few of frequency domain diagrams are typical. Due to the spindle speed
switch frequency is 12.5 Hz, the experiment of the cutter material has two teeth and the switch
frequency is 25 Hz. It can be seen the frequency of 125Hz or 200 Hz and 550 Hz, in the early or mid
time of the tool wear degree difference is not big, but have great peak. Contrasting with the wear of
late, the frequency of the tool’s wear is not as high as the frequency of 25 Hz or more than the set
value, that’s said the tool wear badly. These as shown in figure 8 ~ 13 stages time frequency
domain[7].

4
2nd International Conference on Design, Materials, and Manufacturing IOP Publishing
IOP Conf. Series: Materials Science and Engineering 220 (2017) 012038 doi:10.1088/1757-899X/220/1/012038
1234567890

5. Conclusion
Through the analysis of the relevant, the vibration signal can be observed from the time domain and
frequency domain in the figure. In the early or middle time of the tool wear degree, the difference is
not big, but the middle is relatively stable. The late vibration is more intense. According to the
different vibration signal, the cutting tool indicates different wear state[8]. In the time domain
parameters, the mean square amplitude, waveform of index and kurtosis distinguish from the cutting
tool wear state. In the frequency domain parameters, the mean square frequency and power spectrum
centroid of the cutting tool wear have obvious corresponding characteristic. The example proves that
the time domain and frequency domain analysis method can effectively extract the characteristics of
the cutting tool and identify the quality problems of the cutting tool wear. To a certain extent, the
method improves the accuracy of tool wear monitoring in real time.

Reference
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machine tools and automatic processing technology.
[2] Zhuang Z 2009 Based on the method of acoustic emission and vibration state of tool wear
detection research Shanghai: Shanghai Jiaotong University.
[3] Zhang C 2010 CNC machine tools typical fault analysis and diagnosis system design Qingdao:
Qingdao University of Science and Technology 16-22.
[4] Dominik I, Iwaniec M and Lech L 2013 Low frequency damage analysis of electric pylon
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[5] Dimla D E 2000 Sensor signals for tool -wear monitoring in mental cutting operrations-a review
of mental International Journal of Machine Tools & Manufacture 40(8) 1073-1078.
[6] Ghani J A, Rizal M, Nuawi M Z, Haron C H C, Ramli R 2010 Statistical analysis for detection
cutting tool wearbased on regression model in Proceedings of the International
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[7] Scheffer C, Kratz H, Heyns P S, Klocke F 2003 Development of a tool wear-monitoring system
for hard turning International Journal of Machine Tools and Manufacture 43(10) 973-985.
[8] Chiu M C 2014 Numerical assessment of rectangular side inlet/outlet plenums internally
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