Sweeping filters and tooth rotation energy estimation (TREE) techniques for machine tool condition monitoring

This paper presents a method for the condition monitoring of the milling cutting process based upon a combination of two techniques; sweeping filters and tooth rotation energy estimation (TREE). Existing spindle speed and spindle load signals from the machine are used thus avoiding the need for any additional sensors. The sweeping filter technique determines the frequency components of the spindle signal using low cost hardware. The filter's cut off frequency is swept across a range of frequencies and its output is acquired and analysed in real time. The variations of individual tooth energies estimated by the TREE technique in the time domain are used to verify the results. The hybrid approach created is based on the verification of any indicated faults before making a final conclusion about the health of the cutting tool. This provides a robust and reliable tool monitoring system that is able to identify tool breakage in real time during machining operations.