Intelligent Tool Holder Design: Effective Management of Tool Wear Through Real-Time Monitoring During Machining Processes

Abstract

In the field of mechanical machining, measuring cutting force has become increasingly important. As the tool wears during the machining process, it can cause damage and require timely replacement. However, excessive and frequent tool changes can prolong overall processing time and lead to cost wastage. Moreover, if the timing of tool replacement is too late, it may also affect the quality of machining and reduce cost-effectiveness. Currently, most mechanical machining factories still rely on experienced engineers to judge whether the tool needs to be replaced by observing and listening to the machining process. This not only requires a lot of manpower and time costs but can also result in misjudgments. To address the problem of the inability to measure data in real-time during the machining process, this paper proposes a smart tool holder design that installs a sensing system inside the tool holder. The system uses a three-axis accelerometer to measure and analyze data. Additionally, the design uses a wireless power transmission system to provide power to the entire system and wirelessly transmit data to the host for signal processing and analysis. By displaying data through a window interface, the system can achieve real-time monitoring and is expected to have advantages such as fault diagnosis, improved accuracy, and reduced human costs.