Using a five-axis machining center (GMU-800 series), tests were conducted on the machining of a typical impeller (aluminum alloy);

A

For the roughing operation, the iKIT-HSK63-HSK63-119-H(KYO)-3 was coupled with the iKIT-HSK63A-ER25-130-40-H(KTmix)-7 to measure the force behavior during machining process. The iKIT-Cube-Rect-Acc-T was placed on the rotary table to acquire the three-directional vibration signals. The highly consistent measured values of F and M demonstrate the measurement accuracy and stability of the wireless toolholder. Furthermore, a twofold difference was observed between the two-way bending moments, which is closely correlated with the distance to the actual machining location. This phenomenon indirectly verifies the high sensitivity of the toolholder.

B

For the finishing operation, the iKIT-HSK63A-SLK12-165-H(WSKT)-1 was employed to monitor the force behavior during machining process, while the iKIT-Cube-Rect-Acc-T was placed on the rotary table to acquire triaxial vibration signals. Notably, the polar plot reveals the cutting edge of the tool in use, providing a powerful visual reference for the real-time analysis of tool wear. As the finishing process involves the tilting motion of the rotary table, the data acquired by the wireless testing node allows for a more intuitive perception of the triaxial vibration signals. In subsequent developments, the machining toolpath will be acquired synchronously, and the vibration and strain signals will be overlaid onto it, thereby enabling comprehensive real-time visualization of the machining status.