Tool Condition Monitoring in End Milling of Ti-6Al-4V Using Multisensory Approach

The present work focuses on cutting tool condition monitoring of end milling cutter, using multisensory approach in machining of Ti-6Al-4V. Indirect process parameters such as cutting forces and spindle current are measured as responses using different sensors. Face milling operations are performed on CNC vertical milling center and correlation coefficients are determined to associate tool wear with multiresponse. Systematic plan of experiments was developed using central composite design (CCD) under response surface methodology (RSM) with cutting speed, feed rate, and depth of cut as design variables. Subsequently multisensor-based response surface model was developed in addition to cutting variables. Analysis of variance (ANOVA) was performed to evaluate statistical validity as well as significant variables over the tool wear. Coefficient of determination (\(R^{2}_{\text{adj}}\)) value of 98.28% shows that model correctly explains the experimental results and it behaves well even when adjustment is made in factors, or some factors are added or eliminated. The analysis shows that the measured responses such as cutting forces and spindle current can be used as indirect process parameters for tool wear monitoring in end milling operation of Ti-6Al-4V.