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Detection of Cutting Phenomena Using Sensor Fusion



John A. Slotwinski, Gregory W. Vogl, Robert W. Ivester, Ian Younker


This paper presents an investigation of the application of a suite of sensors for simultaneous in-situ measurements of machining processes. While not every individual sensor responds to all machining phenomena, the suite of sensors together responds to many machining phenomena of interest, including chip segmentation, chip breakage, and vibrations. The simultaneous use of a suite of sensors with modest data-acquisition equipment and the use of careful preliminary laboratory testing for optimizing sensor performance distinguishes this present proof-of-concept work from prior process monitoring efforts using individual sensors. This paper includes discussion of pre-deployment laboratory measurements and a full description of the instrumented tool holder, associated circuitry, and data analysis methods. The deployment of multiple sensors of varying sophistication and cost lays a technical foundation for the ultimate objective of industrially practical measurement and monitoring systems for metal cutting processes.
Proceedings Title
Proceedings of the ASME 2012 International Manufacturing Science and Engineering Conference
Conference Dates
June 4, 2010-June 8, 2012
Conference Location
South Bend, IN


Sensor Fusion, Cutting Phenomena, Chip Segmentation, Accelerometer, Acoustic Emission Sensor, Ultrasonic Sensor, Strain Gage


Slotwinski, J. , Vogl, G. , Ivester, R. and Younker, I. (2012), Detection of Cutting Phenomena Using Sensor Fusion, Proceedings of the ASME 2012 International Manufacturing Science and Engineering Conference, South Bend, IN, [online], (Accessed April 12, 2024)
Created June 8, 2012, Updated February 19, 2017