Decoding Multidimensional Machining Loads: iKIT Wireless Extrasensory Toolholder and Parametric Analysis in Aluminum Cutting

Smart manufacturing requires real-time monitoring of multidimensional forces at the interface between the tool and workpiece in computer numerical control (CNC) machining. In this study, an innovative iKIT wireless extrasensory toolholder is introduced that is capable of high-fidelity, in situ, high-frequency sensing and monitoring of the cutting force, torque, and two-way bending moments. The hardware design of the system is outlined, highlighting a high-bandwidth miniature wireless transmission method and noncontact power supply and energy storage solution suitable for rotating machining environments. To assess the system performance, comprehensive milling tests were performed on aluminum alloy materials, and the relationship between the process parameters and changes in multidimensional mechanical loads was thoroughly examined. The experimental findings demonstrate that the smart toolholder detects precisely how parameter variations affect the loads. Multidimensional mechanical signals (torque and two-way bending moments) show a strong positive correlation with the feed rate and axial depth of cut, confirming the impact of the material removal rate on the system loads. Conversely, these signals are negatively correlated with spindle speed, accurately reflecting the effects of thermal softening and a reduced friction coefficient in aluminum alloys during high-speed cutting. This study not only offers a dependable hardware framework for integrating miniaturized sensors into toolholders, but also delivers accurate data to support digital twin models and adaptive control in machining processes.