Damage Detection in Machining Tools Using Acoustic Emission, Signal Processing, and Feature Extraction

The wear of tools in machining is one of the primary issues in manufacturing industries. Direct measurements of tool wear, such as microscopic observation, lead to increased machine downtime and reduced production rates. To improve this situation, real-time tool condition monitoring systems (TCMs) are needed, which utilize indirect measurement of tool wear through sensors and signal processing. This project focuses on the use of acoustic emission (AE) sensors for experimental analysis of tool damage under various milling conditions. The proposed approach involves designing condition indicators to quantify this damage by implementing infinite impulse response (IIR) digital filters, specifically Butterworth filters, and fast Fourier transform (FFT), in addition to root mean square (RMS), using different frequency bands of the acoustic signals collected during the process. The results from implementing this study show promise for optimizing the process through an alternative TCM system in manufacturing operations, avoiding the drawbacks of the direct method, and extending the equipment’s lifespan and efficiency. It’s worth noting that this document presents partial results of this implementation, which is still in progress.