Abstract: A time series model for on line detection of tool faiture has been developed for general milling operations. The deterministic Components of milling forces are first separated by using fundamentals of milling mechanics, with the remaining force signal being tracted by a first order adaptive autoregressive time series filler or the second difference filter. The filter allows sepertion of milling transients (entry, exit, over holes, slot and other geometric transients on workpiece) from a tool breakage event. The efficient response of the algorithm allows the detection of tool failture within one revolution. The results of laboratory experiments performed confirm the practical applicability of the monitoring algorithm.

Key words: Breakage, Detection, Difference, Milling operations, Milling tool