Ploughing detection in micromilling processes using the cutting force signal

A new method is presented for detecting the onset of ploughing during micromilling on the basis of the cutting force signal. The method utilises the variation in the peak values of the cutting force. Multiresolution analysis with the undecimated wavelet transform is used to detect the peak values of the cutting force signal. A ploughing-detection algorithm is developed, which compares the normalised variance in peak values with preset thresholds. The proposed method is verified by comparing the surface roughness of the sidewall under ploughing and normal cutting conditions in sidewall-machining experiments with a micromilling tool.