Method for determining edge chipping in milling based on tool holder vibration measurements

Process monitoring and in-process control in milling requires reliable sensor data from rotating tooling systems. Vibration sensing by an instrumented tool holder close to the cutting zone has been proven useful in mitigating chatter. A model is presented that enables the interpretation of vibration data of the rotating sensor and tool system to identify edge chipping. Thus, data from a single axis accelerometer can be interpreted to identify the existence of edge chipping on one of multiple cutting edges. The classification of observed effects is derived from methods developed for machine learning, which is demonstrated and evaluated by experimental results.