Savings from the use of tool monitoring

Main potentials

Extension of the tool change interval based on the ability to detect wear early.
Ability to economically re-sharpening because of timely tool changes.
Avoiding of tool breakage.
Option of hazard-free experimentation with different tool types and grinding specifications.
Ability to use more economical tools as premature tool life ends is indicated as appropriate.

Ability to have unsupervised runs during breaks or production in a semi-supervised 3rd shift.
Lower machining cycle time because higher feed rates are possible.
Operation with few disturbances through avoidance of breakage and “clearing” on the following stations.
Reduction in air cutting: reduction in machining time through the use of higher feed speeds until cutting begins (is especially common for grinding).
Gap elimination: Lower machining cycle time because higher feed rates are possible before first cut initiating.
Measurement curve display covers premature switchover points from high-speed to working feed speed.

In-process work piece dimension control with pneumatic measurement probes, a lathe tool or the RST as probes (acoustic contact detection via the slide noise on the rotating work piece).
Detection of false dimensions by monitoring different acoustic emission.
Improvement in surface quality through detection of chatter.
In production tool wear and breakage control with immediate stop.
The visualization of the process on the monitor often allows detection of irregularities just by looking at the measurement curve.

Detection of short pieces due to other process irregularities and sorting them out with control of a scrap gate.