Tool wear monitoring of micro-milling operations

The mechanical removal of materials using miniature tools, known as micro-mechanical milling processes, has unique advantages in creating miniature 3D components using a variety of engineering materials, when compared with photolithographic processes. Since the diameter of miniature tools is very small, excessive forces and vibrations significantly affect the overall quality of the part. In order to improve the part quality and longevity of tools, the monitoring of micro-milling processes is imperative. This paper examines factors affecting tool wear and a tool wear monitoring method using various sensors, such as accelerometers, force and acoustic emission sensors in micro-milling. The signals are fused through the neuro-fuzzy method, which then determines whether the tool is in good shape or is worn. An optical microscope is used to observe the actual tool condition, based upon the edge radius of the tool, during the experiment without disengaging the tool from the machine. The effectiveness of tool wear monitoring, based on a number of different sensors, is also investigated. Several cutting tests are performed to verify the monitoring scheme for the miniature micro-end mills.