Abstract: In the aerospace field,critical structural components such as cavities and ribs are often manufactured from aluminum alloys. These parts are highly susceptible to temperature fluctuations and vibrations during milling operations,which can lead to degraded machining quality and reduced tool life. To address these challenges,a self-inductive smart tool holder system based on the Halbach array is designed for collaborative measurement of temperature and vibration. An embedded K-type thermocouple temperature measurement subsystem is fabricated using femtosecond laser processing and high-temperature curing techniques. A MEMS triaxial accelerometer is integrated into the rotating central shaft of the smart tool holder to achieve high-sensitivity vibration signal acquisition. Milling experiments are subsequently carried out with the developed smart tool holder system. The results indicate that the system can be powered at 1 000 r/min. Temperature and vibration data during machining are acquired in real time through an upper computer,confirming the system's high reliability and stability. The temperature measurements show higher accuracy compared to those obtained with an infrared thermal imaging camera. Based on the measured temperature,the dynamic heat source intensity in the tool-chip contact zone is inversely deduced,and the temperature field is reconstructed. The error between the predicted and actual temperature curves is maintained within 8%. The reconstructed temperature field allows prediction of the location of the maximum temperature on the rake face. The findings provide a new method for real-time perception and monitoring of tool condition in milling operations.

Key words: Halbach array, cutting temperature, cutting vibration, self-inductive smart tool holder, milling process