Research On The Application Of Multi-sensor Information Fusion Technology On Milling Process Monitoring

During the high-speed milling operations of metallic materials, The actual tool condition has an effect on the processing precision and efficiency, and it also makes great influence to the manufacture cost and product quality. So this article presents the multi-sensor information fusion based on vibration sensors and acoustic emission sensors. The extracting method of the signals collected by the test elements of vibration sensors and acoustic emission sensors, which is to identify the tool wear condition during high-milling process. And the process of research and content are as follows:1. The varieties of cutting tool state recognition during the milling process are classified according to tool flank wear. The judgmental criterion of the tool wear states was determinated. Experience with multi-sensor tools for tool condition assessment, the model of multi-sensor information fusion is built based on information fusion theory; It takes much work for the approach to analysis modeling.2. The multi-sensors information fusion algorithm is based on D-S evidence theory. The tool wear status was evaluated quantitatively during metal-milling processes; it gives an index to tool life for the failures of tool wear, breakage and fracture.3. The multi-sensor signals acquisition system based on Lab VIEW software collects sensor signals which are analyzed by Mat lab software to extract the eigenvalue related with the tool wear in the time domain and frequency domain. According to the result complexity measures of the cutting vibration signals and the frequency band energy of the cutting acoustic emission signals, the degree of tool wear can be estimated.4. It is necessary to improve the tool condition monitoring system based on vibration and acoustic emission sensors, and several verification experiments had proved the effectiveness and reliability of the system.The research of this article focused on the information fusion between cutting vibration signals and cutting acoustic emission signals, this method is of simply, rapid, high sensitivity and the less influence of cutting conditions. It is helpful to enrich the fusion theory and improve productivity and security.