A Method of Tool Breakage Detection in CNC High-Speed Milling

Tool condition monitoring, mainly tool breakagedetection for high-speed machining (HSM), is an importantproblem to solve; however, the techniques or types ofsensors applied in other research projects present certaininconveniences. In order to improve tool breakage monitoringsystems, a simple, effective, and fast method ispresented herein. This method is based on the discretewavelet transform (DWT) and statistical methodologies. The effectiveness of the method is based on the measurementsof the feed-motor current signals using inexpensivesensors. It is well-known that during the cutting process,the motor current is related to the tool condition.