Tool condition monitoring in an end-milling operation based on the vibration signal collected through a microcontroller-based data acquisition system

Machine condition plays an important role in machining performance. A machine condition monitoring system will provide significant economic benefits when applied to machine tools and machining processes. Development of such a system requires reliable machining data that can reflect machining processes. This study demonstrates a tool condition monitoring approach in an end-milling operation based on the vibration signal collected through a low-cost, microcontroller-based data acquisition system. A data acquisition system has been built through interfacing a microcontroller with a signal transducer for collecting cutting vibration. The examination tests of this developed system have been carried out on a CNC milling machine. Experimental studies and data analysis have been performed to validate the proposed system. The onsite tests show the developed system can perform properly as proposed.