Face milling tests were conducted using the iKIT-BT40-BT40-155 toolholder on 304 stainless steel, utilizing a 10 mm 4-flute milling cutter. The cutting parameters were set as follows: a feed rate of 800 mm/min, a spindle speed of 3500 rpm, and a depth of cut of 0.2 mm.

To ensure the validity of the acquired experimental data, the tool runout was measured after clamping, yielding a value of 0.014 mm. Relying on the in-situ synchronous data display of our self-developed software, users can observe the real-time dynamics of the four sets of signals by adding a time-series chart, or utilize a polar plot to assist in evaluating the cutting condition of the tool flutes. A set of sample blocks was machined during this experiment. Toward the end of the designated tool path, it was observed in the polar plot that the representations of the cutting edges became smoother, contrasting with their initial sharp state, and the signal amplitude increased by nearly 1.5 times. This characteristic indicates that tool wear may have occurred. To verify this hypothesis post-experiment, morphological imaging of the tool was conducted, which revealed distinct wear on the cutting edges.

Following the experiment, to validate this predictive hypothesis, morphological imaging of the cutting tool was conducted. The images reveal significant wear on the tool's cutting edge angle, highlighted by the framed area in the photograph. By analyzing the actual machining path, it is determined that under the current machining conditions, the tool life for this specific cutting tool is 33,600 mm. Therefore, the intelligent tool holder and software developed by our company serve as powerful tools that effectively assist users in monitoring tool operational status.

In addition to monitoring tool wear, the system is equally capable of detecting abnormal machining conditions such as tool chipping, chip clogging in the tool holder, and chip entanglement. The development of this product breaks through the bottleneck of intelligent machining, enabling precise quality monitoring and promoting highly efficient production.