An innovative tool-monitoring system (MICROM) to detect drastic tool failures in micro-milling

Process monitoring becomes critical for micro-milling when increased productivity and high quality microstructured parts are aimed to be obtained. Traditionally used monitoring methods during conventional machining are no more suitable for micromilling operations, and new monitoring systems are hence needed. An innovative process-monitoring system called MICROM (Machine Impedance Change based Robust On-line Method) has been developed and presented in this paper. The working principle of the proposed system is described, and the main advantages and disadvantages are discussed in the following sections. The proposed MICROM monitoring system has multiple functionalities and diverse fields of application. This paper focuses on the capability of the system to detect tool breakages in micromilling operations because unpredictable tool life and premature tool failure are critical issues that need to be resolved for the successful application of micro-milling technology. Experimental tests have been carried out to detect tool failure, and highly promising results have been obtained, as presented in this study. The MICROM monitoring system has been recently patented and it has proven to be a reliable and cost-effective solution for monitoring machine-tool technologies, and in particular, the micro-milling process. It is expected that the MICROM monitoring system will have a great acceptance and widespread distribution in the market.