This paper describes recent research progress at the University of New Hampshire in the area of “Smart Machining Systems (SMS)”. Our approach to SMS is to integrate models with wireless embedded sensor data to monitor and improve the machining process. This paper discusses recent progress in low-cost wireless sensor development, model calibration methods, model accuracy, and tool condition monitoring for SMS. We describe a system that can estimate tool wear using the coefficients of a tangential cutting force model. The model coefficients are estimated by online measurement of spindle motor power. We also show the use of a cutting tool embedded with a wireless vibration sensor to detect the onset of chatter in real-time.

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