Abstract

In machining operations, dynamometers are typically used to directly measure the forces acting on cutting tools. However, their high cost and complex setup restrict their use to laboratory environments, making them unsuitable for real-time monitoring in general production settings. To overcome this limitation, this study proposes an autoencoder-based learning model for estimating cutting forces using only spindle vibration signals acquired during milling. The model features a deep neural network (DNN) that takes processed spindle vibration signals as input and predicts latent features derived from cutting force signals through an autoencoder. These predicted latent features are then fed into a pretrained decoder to reconstruct the corresponding cutting force signals. To enhance the model's accuracy and robustness, the raw vibration signals sampled at 20 kHz were filtered with a bandpass filter that spans the effective frequency range of 20–2500 Hz, effectively removing irrelevant noise. For validation, an accelerometer was mounted on the spindle head of a milling machine, and vibration data were collected during cutting. The estimated cutting forces were compared to ground truth measurements obtained from a dynamometer. The model achieved a Pearson correlation coefficient of 0.943, demonstrating that reliable cutting force estimation is achievable using only low-cost vibration sensors.

• Keywords: Tool condition monitoring, Cutting force, Spindle vibration, Machine learning, Autoencoder