Optimising Sensor Placement for Tool Condition Monitoring: A Comparative Analysis of Acoustic Emission Data

In the monitoring of machining processes and in the context of tool condition monitoring, the position of acoustic emission sensors affects the quality of the resulting information. This drives this comparative study which presents a comparison of acoustic emission data recorded simultaneously by a sensor attached to the side of the milling table and another sensor near the spindle during a tool wear test on a CNC milling machine. The signal information is clearly influenced by the different positions. Whereas the signals near the spindle are dominated by vibrations of the spindle motor during machining, these strong contributions do not occur in the recorded data of the machining process detected by the sensor mounted to the table. However, the position of the sensor near the spindle has the advantage of maintaining a constant distance to the source of the acoustic emissions of the machining process, as the sensor moves with the tool. In contrast, the sensor attached to the milling table is affected from the fact that the distance to the milling tool is constantly changing. This results in different dominant frequencies, that are analysed in this study. To analyse both the entire frequency range and the higher frequencies, two distinct approaches are employed, one without and one with the use of a high-pass filter. Furthermore, the recorded signals were used to calculate the characteristic features, namely the Partial Powers, thereby enabling assessment of the condition of the tool. The results demonstrate that this single feature type is sufficient for training a machine learning model to predict the tool wear, focusing on the flank wear width. This study analyses the efficiency of wear prediction with respect to both sensors and frequency spectra, and compares the results. In this context, the most accurate predictions were achieved with Gaussian process regression models.