Application of measurement systems in tool condition monitoring of Milling: A review of measurement science approach

Milling is a high-performance method that allows an efficient machining of both flat and complexly shaped surfaces. During the milling process, the cutting tool (cutters), its cutting edges are constantly subjected to tool wear, which affects the accuracy and roughness of the processing. It is important to understand the current condition of the cutting edges and make a decision in time. This review article analyzes the direct and indirect methods of tool condition monitoring, as well as the use of conventional and artificial intelligence (AI) of sensory systems. The force measurements, vibration measurements, acoustic emission sensors, current and power sensors, image sensors, thermal sensors, and others are considered. The advantages, disadvantages, and prospects of using such sensors for milling operations are discussed in this review article. Trends in the application of advanced sensor systems for milling, such as artificial intelligence sensors for the implementation of Industry 4.0, is reviewed in this article.