Integrated piezoelectric WST-spindle system for real-time micro-drill breakage monitoring

This paper presents an innovative integrated piezoelectric wireless signal transmitted (WST) spindle system designed for real-time micro-drill breakage monitoring. Addressing the fundamental challenges of signal attenuation and noise interference inherent in conventional external sensor systems, our solution embeds a highly sensitive piezoelectric sensor directly into the tool holder, ensuring maximum signal fidelity. The system utilizes a Support Vector Machine (SVM) algorithm with a Gaussian Radial Basis Function (RBF) kernel to classify the captured high-fidelity signals. Experimental results demonstrate that this approach effectively overcomes signal attenuation, achieving superior signal quality compared to external accelerometers. The system exhibits a 100% detection accuracy for micro-drill breakage across various materials, including low carbon steel, CFRTP laminates and zirconia. This research provides a robust and practical solution that significantly enhances the reliability of automated, high-precision manufacturing, thereby reducing scrap rates and improving overall productivity.