A comparative study of tool condition monitoring techniques in milling machines

Tool condition monitoring (TCM) plays a crucial role in ensuring the efficient and effective operation of milling machines by preventing tool failure, improving machining quality, and optimizing the overall production process. This paper presents a comparative study of various tool condition monitoring techniques employed in milling machines, including acoustic emission (AE), vibration analysis, force sensing, and image processing methods. Each technique’s effectiveness in detecting tool wear and its practical application in industrial settings are discussed. Furthermore, the advantages, limitations, and future trends of each approach are analyzed. The results provide insight into the selection of appropriate monitoring techniques based on the specific requirements of milling operations.