Recent Progress of Chatter Detection and Tool Wear Online Monitoring in Machining Process: A Review and Future Prospects

The precision and ultra-precision mechanical machining process is accompanied by tool wear, which may also cause cutting chatter and damage the surface quality of the machined parts. The machining quality of the key parts for high-end equipment has a significant effect on its service performance. Monitoring the machining condition is of great significance to ensure the machining quality of the parts. The main processes of the machining condition monitoring include signal acquisition and feature extraction, feature selection, and online monitoring of the cutting condition. Currently, most research focuses solely on chatter detection or tool wear monitoring. This article first introduces the research status of the cutting chatter mechanism and the tool wear mechanism, analyzes the interaction between both, and clarifies the importance of monitoring both conditions simultaneously. Then, to comprehensively monitor the tool condition during machining, this review analyzes the research progress in the recent ten years of online monitoring of the chatter and the tool wear from the aspects of signals acquisition and feature extraction, feature selection, and online monitoring of the tool condition during machining. It provides a consult for the comprehensive monitoring of tool conditions during machining. By analyzing the characteristics of the two category condition monitoring methods, this review focuses on the differences in the feature selection and the online monitoring models in the tool condition monitoring. The direction of research on tool condition monitoring in machining is also discussed, which has a promoting effect on the development of condition monitoring technology in the green manufacturing of key parts in high-end equipment.