This paper introduces an approach to monitoring the milling process using low-cost microcontrollers. The work is based upon a system developed to detect tool breakage. The deployed system continuously monitors the spindle motor drive to acquire, process, and communicate data relating to the work undertaken by an individual cutter. This information is packaged and sent to a central server where it can be managed to provide an accurate record of tool usage. It is proposed that such information can be used more simply than existing tool life calculations to support tool management systems. This has implications for the effective management of cutting tools at the machine tool and factory levels.
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