Critical Aspects in the Application of Acoustic Emission Sensing Techniques for Robust and Reliable Tool Condition Monitoring

Acoustic emission sensing techniques for tool condition monitoring (TCM) in machining processes have been widely studied in recent years. Some approaches have been developed and successfully implemented in industry. However, standard solutions allowing for a quick and easy application of this sensor monitoring method have not been found yet. This is basically due to the great complexity associated with tool wear mechanisms together with critical aspects in the design of cutting tests for tool wear monitoring experimentation and in the set-up of the measurement chain. In this work, the main critical points associated with the definition of the cutting tests for TCM have been analysed. The study has revealed that it is necessary to pay special attention to the previous wear level in the tool and to the way it was achieved. Besides, the need for a standardised methodology for cutting test design, allowing for a better comparison of results obtained through different TCM test procedures, has been evaluated. As a first approach, the minimum set of elements and characteristics that should be included in such standardised methodology has been established.