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IT Detect and prevent tool wear with Montronix systems
With our sensors for power, vibration, and force, you can detect tool wear early and reliably. This protects your machine from unplanned downtime, ensures consistently high machining quality, and extends the service life of your tools. Montronix provides suitable solutions for this application.
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Detecting tool wear: The underestimated risk in production
Tool wear is not a sudden event, but a gradual process. It begins subtly, but its effects usually only appear once damage has already been done: dimensional deviations, surface defects, or downtime due to tool breakage. The challenge is to detect wear in time before scrap or machine damage occurs. That’s exactly why we have developed systems that continuously monitor the condition of your tools.
Types of tool wear
Abrasion: Grinding degradation caused by hard particles
Abrasion occurs when hard particles in the material or environment strike the tool. They act like abrasives and remove material from the cutting edge layer by layer. The cutting edge loses its geometry, impairing the machining process. Studies show that tool wear increases significantly faster with abrasive materials such as cast iron or fiber‑reinforced composites.
Adhesion: Material sticking to the cutting edge
With adhesion, material from the workpiece bonds to the tool and often causes tool wear. A so‑called built‑up edge forms, which changes uncontrollably. This leads to irregular cutting forces, unstable machining conditions, and poorer surface quality. Technical publications confirm that cutting forces and tool behavior measurably change as adhesion increases.
Diffusion: Temperature‑induced dissolution of tool components
At high temperatures, atoms migrate from the tool material into the workpiece material. This diffusion weakens the tool’s microstructure and reduces its hardness. This effect is particularly pronounced in high‑performance machining. Tools lose their cutting ability even though they may appear intact externally.
Oxidation: Reaction with oxygen under heat
At excessive temperatures and with insufficient cooling, the metal components of the tool react with oxygen. Oxide layers form and deposit on the surface. These layers act as insulation, increase friction, and impair heat dissipation. The tool wears faster and more unevenly.
How can tool wear be detected?
Our systems detect the smallest changes in the machining process before they cause problems. We combine three types of sensors for maximum insight:
Power Sensor PS200-NG
The PS200-NG measures active power directly on the spindle and feed drives. The sensor detects even the smallest changes in the force curve, e.g., with dull cutting edges or unsuitable material. It immediately reports this deviation to the system. This helps you avoid scrap and detect tool wear long before dimensional accuracy is affected.
Special features:
- Responds to ±0.25% power change
- Operates independently of the control system
- Direct connection via M8 connector
- Ideal for series production and small milling tools
Vibration Sensor Pulse Plus
The Pulse Plus is a 3D accelerometer sensor that measures vibrations in all three spatial axes (X, Y, Z). If the vibration behavior of a tool changes — e.g., due to initial wear or imbalance — the sensor reports this change in real time. This allows you to detect process deviations before damage occurs. The sensor is also particularly effective for collisions and bearing damage.
Special features:
- MEMS technology with 3‑axis measurement
- Data rate up to 26,667 values/second per axis
- Mounting with magnetic base or screw thread
- Ideal for machining centers, grinding machines, robots
Force Sensor RetroBolt
The RetroBolt measures the actual cutting force on the tool. If the force deviates from the reference — e.g., due to dull cutting edges or chip jamming — the system triggers an alarm. The sensors can be integrated directly into existing machines, for example under screw connections. Especially in turning processes, the RetroBolt provides highly precise information about tool load and makes early tool wear visible.
Special features:
- Direct mounting under existing screw points
- High resolution even for micro‑chipping
- Can be combined with Spectra ONE for evaluation
- Usable in multi‑spindle and special machines
Overview of components for tool wear detection
Why monitoring tool wear is worthwhile
Avoid scrap and rework
Our system detects tool wear at the very first increase in cutting force or power. This allows you to stop machining before the first defective part and avoid costly rework.
Reduce tool costs
You use each tool precisely up to its actual wear limit instead of replacing it prematurely across the board. This typically saves an average of 15 to 30% of tool costs per machine.
Make maintenance plannable
The system documents gradual changes in the process over weeks. You can see when a tool becomes critical and replace it specifically during the maintenance window.
Increase machine availability
Real-time alerts prevent downtime due to tool breakage or spindle damage. Your machines run reliably, even in unmanned operation or with frequent staff changes.
Typical applications
Our systems are suitable for all industries with machining, automation, or high quality requirements. Anywhere tools are in use and their condition is critical.
- Milling centers benefit from precise detection of tool wear even with small tools.
- Lathes ensure machining quality in long production runs and with changing materials.
- Grinding machines detect irregularities in tool condition particularly early.
- Automated lines avoid series defects through continuous monitoring.
- Special-purpose machines receive customized sensor solutions for specific requirements.
Our services
- System consulting & configuration: We analyze your requirements and recommend the right components, taking into account machine type, process, control system, and budget.
- Installation & commissioning: Our technicians assist you during installation. The systems can be retrofitted quickly, even with minimal intervention in the control system. Commissioning usually takes place within one working day.
- Trial setup & pilot projects: Want to see how well it works first? No problem. We can provide our system for testing.
- Training & support: We train your staff in its use and provide the know-how for safe operation. We are always available to answer questions.
Contact
Do you want to know which system is right for your machine? Or start a pilot project right away? Then write to us or call us. We provide individual, practical advice.
Send request nowFAQ: Frequently asked questions about tool wear and our systems
How exactly does the system detect wear?
The system continuously compares current process data with previously determined reference values. As soon as key figures such as power, force, or vibration change measurably, the evaluation unit detects this deviation. Gradual changes, which operators often do not notice, are particularly typical of early tool wear. The sensors respond to these signals in real time and report the condition before dimensional deviations or tool breakage occur.
Is the system also suitable for older machines?
Yes, our sensor solutions are designed to be completely control-independent. They require no special CNC interface and can be integrated directly via inputs and outputs. Especially for older machines without integrated monitoring systems, this represents a significant upgrade. Many customers retrofit their existing systems within a day, without any intervention in the machine logic.
How long does installation take?
Installation usually takes only one working day per machine. The sensors are compact, easy to mount, and connect directly via preconfigured plugs. Calibration or manual adjustment is usually not necessary, as many systems operate with a learning mode. Even in retrofit projects, installation is straightforward without significantly interrupting production.
Do I need to teach the system?
Yes, at the start you record a reference cycle of two to three parts, which serves as the basis for later evaluation. This process takes place directly in production. The system then operates in a learning-based manner, automatically detects new tools, and adjusts the limits for the new tools accordingly. The operator does not need to make any complex settings.
Can I test the system before purchase?
Yes, we offer a trial installation directly on your machine if desired. This allows you to experience the functionality in your own environment with your workpieces and processes. Our experts assist with installation and show you exactly how to record and interpret wear data. This lowers the entry barrier and gives you confidence in your investment decision.