A Milling Stability Monitoring System Based on a Dynamic Force-Sensing Vise
Journal
IEEE Sensors Journal
Journal Volume
25
Journal Issue
21
Start Page
40525
End Page
40536
ISSN
1530437X
Date Issued
2025
Author(s)
Abstract
Traditional machining stability assessments, typically relying on accelerometers, acoustic emission (AE) sensors, microphones, or dynamometers, encounter persistent limitations. These include high costs, complex deployment and signal conditioning, susceptibility to environmental disturbances, and a narrow focus on simple go/no-go chatter classification. To address these challenges, this work introduces a cost-effective milling stability monitoring system that integrates a dynamic force-sensing vise with a singleboard computer. The system employs a simplified single-axis sensing approach, strategically designed to avoid interaxis crosstalk errors common in multiaxis configurations. The sensor achieves 1.3 mV/N sensitivity and 4.6% linearity error over ±800 N, performance levels demonstrated to be sufficient for stability evaluation. A low-power edge computer processes conditioned signals in real time using a computationally efficient stability index (SI), which quantifies vibration severity with substantially reduced computational load compared to conventional algorithms, enabling fast and energy-efficient operation. Experimental validation confirms the capability of the method to detect high-frequency chatter in small-diameter milling with uniform-pitch tools. The integrated system therefore offers a practical and accessible solution for real-time, on-machine stability quantification, providing a reliable means to enhance cutting condition assessment in industrial computer numerical control (CNC) machining applications.
Subjects
Chatter detection
dynamic cutting force sensing vise
embedded system
machining stability
Publisher
Institute of Electrical and Electronics Engineers Inc.
Type
journal article