Investigation of the Influence of Sensorized Tool Holders on Dynamic Properties and Manufacturing Results During Milling

Monitoring process stability and tool condition is essential for ensuring machining quality and efficiency. This study investigates the influence of sensorized tool holders on dynamic properties and machining results. Three clamping conditions, one conventional and two different sensor-integrated tool holders (equipped with strain gauges or piezoelectric force sensors), are compared. Experimental modal analyses are carried out to determine the frequency-dependent dynamic compliance of the systems. Machining tests using a developed reference workpiece enable the investigation of process forces, wear development, and the surface quality achieved under real conditions. The results show that the dynamic behavior of the tools varies significantly depending on the respective excitation frequency, whereby the different structural properties of the tool holders have a clearly measurable influence on their dynamic properties, particularly near process-relevant excitation frequencies. However, no clear deterioration in terms of process stability or machining performance can be determined. In some cases, the sensorized tool holders can contribute to reduced tool wear and improved process stability. These findings emphasize that sensorized tool holders do not necessarily worsen the machining results and can be applied without negative effects when aligned with the system’s modal characteristics.