Monitoring of vibrations and cutting forces with spindle mounted vibration sensors

This paper presents a method to estimate the cutting forces and vibrations at the milling tool from accelerometers mounted on the spindle housing. The frequency response functions between the spindle nose and accelerometer locations are identified once with impact modal tests. Cutting tool and holder is assembled with the speed and preload dependent spindle structure dynamics using receptance coupling. The distortion of signal transmission from tool to the accelerometer location is compensated with a Kalman filter to estimate the forces and displacements at the tool tip. The proposed method is experimentally demonstrated in milling tests. The cutting force and displacement estimations were within 80% of the directly measured values. (C) 2019 Published by Elsevier Ltd on behalf of CIRP.