Two-dimensional monitoring system for tool behavior in end milling with small diameter tool

This report presents a two-dimensional monitoring system for precise process control of end milling processes involving the use of a small-diameter tool. The system enables the measurement of tool deflections and cutting forces in two directions: the cutting or tangential direction and the feed or normal direction. The use of this system to measure periodic change in tool deflection during a given turn is also presented. In an experiment, this system was applied to the end milling of a steel plate at different cutting speeds, depths of cut, and feed rates. Results indicated that this system enabled the in-process monitoring of tool deflection and the measurement of cutting force. They also demonstrated that the tool deflection and cutting force increased with the feed rate and depth of cut. Results of the in-process measurement of tool deflection suggest that the periodic change in tool deflection during a given turn is related to the rotation angle of the tool and the number of tool edges. These results also suggest that two-dimensional information and information on the periodic change in tool deflection with changes in the rotation angle must be taken into account when monitoring tool behavior and tool breakage.