Process monitoring and impulse detection in face milling using capacitive acceleration sensors based on MEMS

High-performance acceleration sensors acquire increasing relevance for process monitoring and crash detection. In this regard, a newly developed sensor system is realised comprising an 8 kHz and a 20 kHz high-acceleration MEMS-based sensor. This research presents proof of functionality of the sensor system conducting cutting experiments and impulse detection tests. For cutting tests, a 42CrMo4 steel grade is machined with cemented carbide milling tools. The process data indicate that distinct cutting processes stages and crash related impulses can be recognised reliably. As general functionality is proven, the sensor system can be evolved for industrial process monitoring and crash detection applications.