Testing of a high-precision intelligent data monitoring kit for machining

This paper presents the development of an intelligent toolholder, an in-situ process monitoring kit, capable of simultaneous high-frequency measurement of cutting force, torque, and two-directional bending moments. Through structural optimization, the system achieves high sensitivity, high precision, and reduced crosstalk in targeted sensing directions. The structural rigidity of the design was verified through both static and dynamic stiffness tests. Static calibration results show that the monitoring kit exhibits strong performance in terms of sensitivity, linearity, hysteresis, and repeatability. In addition, its decoupling capability surpasses that of existing toolholder systems, with a maximum crosstalk error of only 4.2%. In end-milling experiments, the kit demonstrated robust performance in detecting dynamic cutting-force signals. Overall, the intelligent monitoring kit offers enhanced transparency in the cutting process and holds significant potential as a practical tool for process optimization, productivity improvement, and quality assurance.