The cutting parameters dependent vibration monitoring method for machine tools

The on-line monitoring of the machine tools attracts growing interest for the operation of the smart factories. The quality of the workpieces and the productivity of the manufacturing can be maintained through the monitoring and optimization. The vibration signal reflects irregular characteristics of the fault conditions, such as the tool wear and chatter. The corresponding features can be extracted and recognized using the conventional signal processing method in the time and frequency domain. However, the vibration features are process-dependent. Due to the dynamic changes of cutting parameters, the variance of the cutting forces and the consequent frequency response between different cutting parameters could be larger than that between the regular conditions and fault conditions in the identical cutting parameters. This paper combined the vibration signal with the real-time cutting parameters and toolpath calculated by the numerical control codes to analysis the cutting condition of the machining process. A sub-band segmentation method based on spindle speed is proposed. The accuracy and applicability are also discussed.