FPGA-based reconfigurable system for tool condition monitoring in high-speed machining process

•We present a tool condition monitoring system in high-speed machining process.•The system implementation is compact.•The system is economical because its cost is under US$200.00.•The system is reliable. The results showed 100% detection of tool conditions.

We present a reconfigurable system to detect and indicate online and in real time, the cutting tool conditions in high-speed face milling. It consists of a data acquisition system (DAS) and a hardware signal processing (HSP) unit. The DAS acquires and digitalizes the cutting vibration signals generated from machining tests performed under different tool conditions and cutting parameters. The HSP unit processes the digitalized vibration signals using reconfigurable IIR band-pass digital filter and statistical techniques, designed and implemented into a single field-programmable gate array (FPGA) and coefficients read-only memories. The system operation is divided into learning and monitoring modes. The tool condition is indicated by an alarm signal, one LED indicator, and a message shown on four-digit seven-segment displays. In all experiments, the system correctly detected the tool condition. The proposed system is fast, compact, reliable, and economical, and no modification of the machine-tool structure is required.

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