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== Techniques of machine tool monitoring ==
Machine tool monitoring can be done with or without additional [[Sensor|sensors]]. Using additional sensors, monitoring can be done by measuring:
* the cutting force (with a multi-channel table [[dynamometer]] or rotating dynamometer)<ref>{{Cite journal|last=Jemielniak|first=K.|last2=Arrazola|first2=P.J.|date=January 2008|title=Application of AE and cutting force signals in tool condition monitoring in micro-milling|
* [[vibration]] amplitude using multi-channel [[Accelerometer|accelerometers]]<ref>{{Cite journal|last=Haber|first=R.E.|last2=Jiménez|first2=J. E.|last3=Peres|first3=C.Ronei|last4=Alique|first4=J. R.|date=2004|title=An investigation of tool-wear monitoring in a high-speed machining process|
* audible sound from the machining process
* [[High frequency|high-frequency]] sound or [[acoustic emission]]<ref>{{Cite journal|last=Li|first=Xiaoli|date=January 2002|title=A brief review: acoustic emission method for tool wear monitoring during turning|
Sensor-less machine tool monitoring is done by measuring internal drive signals such as:
* feed motor [[Electric current|current]]
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An AE sensor detects force proportional monitoring signals even in machining operations, which generate very small cutting forces. In combination with true power, it increases the reliability of breakage monitoring.<ref>{{cite book|last1=arbor|first1=ann|title=MTC tool and process monitoring|date=1997|publisher=Artiscompany|___location=USA}}</ref> It is used especially with solid [[carbide]] tools, or very small tools on large machines and multi spindles. Most of the sensors have to be attached to the machine tool surface.<ref>{{cite book|last1=hur|first1=Winter|title=Piezo-instrumentation|date=1997|publisher=Kistler company|___location=Switzerland}}</ref> However, there are alternative methods of AE wave transmitting. A rotating, [[wireless]] AE sensor consists of a rotating sensor and a fixed receiver.<ref>{{cite book|last1=Aachen|title=Wireless AE sensor AEL 200|publisher=Prometec company|___location=Germany}}</ref> An AE sensor can also receive the acoustic waves via a jet of cooling [[lubricant]], which can be connected directly to the tool or workpiece.<ref>{{cite book|first1=|title=Nordmann sensor technology|date=1997|publisher=Nordmann company|___location=Germany}}</ref><ref>{{cite book|title=Fluid sound sensor WAE 100|publisher=Prometec company|___location=Aachen, Germany|edition=Aachen, Germany: Prometec company}}</ref>
The machine tool monitoring systems commonly use sensors for measuring cutting force components or quantities related to cutting force (power, [[torque]], distance/[[Displacement (geometry)|displacement]] and strain). AE sensors are relatively easy to install in existing or new machines, and do not influence machine integrity and stiffness. All systems suppliers also use acoustic emission sensors, especially for monitoring small tools<ref>{{Cite journal|last=Beruvides|first=G.|last2=Quiza|first2=R.|last3=del Toro|first3=R.|last4=Haber-Guerra|first4=R.E.|date=2013|title=Sensoring systems and signal analysis to monitor tool wear in microdrilling operations on a sintered tungsten–copper composite material|
All sensors used in machine tool monitoring systems are well adjusted to harsh machine tool environments. The difficulties in designing reliable machine tool monitoring can be related to the complexity of the machining process itself, which may have one or more of the following characteristics, apart from the changes of the machine tool itself.<ref>{{cite journal|last1=Dimla|first1=Dimla E|title=Sensor signals for tool-wear monitoring in metal cutting operations–a review of methods|journal=International Journal of Machine Tools and Manufacture|date=2000|volume=8|issue=40|page=1073|doi=10.1016/S0890-6955(99)00122-4}}</ref>
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