Date of Award

Spring 2011

Project Type


Program or Major

Systems Design Engineering

Degree Name

Doctor of Philosophy

First Advisor

Barry Fussell


A first step towards practical sensing in the machining environment is the development and use of low cost, reliable sensors. Historically, the ability to record in-process data at an end mill tool tip has been limited by the sensor location. Often, these sensors are mounted on the material workpiece or the machine spindle at significant physical distance from the cutting process. Of specific interest are the problems of tool chatter which causes limitations to productivity and part quality. Although tool chatter is a substantial issue in machining, it remains an open research topic. In this research, a sensor integrated cutting tool holder is developed to specifically analyze the problems related to tool chatter.

With the sensor integrated cutting tool holder, the signal to noise ratio is higher than traditional sensing methods. Because of the higher sensitivity, new data analysis methods can be explored. Specifically, the sensor is used in conjunction with a data dependent linear predictive coding algorithm to demonstrate effective prediction of chatter frequencies from stable cutting.