Sensors-Embedded Cutting Tools to Accelerate Digital Transformation in Cutting Processes

During cutting processes, cutting edges cannot be directly observed, leading to reliance on skilled workers' intuition and experience for optimizing cutting conditions. In recent years, sensors equipped in machine tools have been utilized to comprehensively monitor machining conditions including cutting forces. However, their sensitivity and accuracy are insufficient due to distance between the cutting point and measurement position.

To address this challenge, we have developed “Sumi Force,” a sensing tool that measures cutting forces in real-time by embedding strain sensors in the tool holder, where inserts, drills, or end mills are held, closest to the cutting point. The measured data is wirelessly transmitted outside the machine tool, enabling easy integration to various machines and production lines used by customers. This paper introduces a new solution service that utilizes “Sumi Force” to optimize machining processes for customers, and discusses the development of techniques to detect anomalies such as tool wear and breakage based on changes in cutting force.

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Excerpt from Sumitomo Electric Industries Technical Review No. 100 published in April 2025.

Keywords: cutting, process monitoring, sensor, cutting force, anomaly detection