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Experimental Validation of EMIS-Based Frequency Tracking for Milling Vibration Monitoring Compared with FFT Analysis

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Abstract:

Effective suppression of vibration is essential for surface quality and tool longevity in machining. This study assesses the viability of Electromechanical Impedance Spectroscopy (EMIS)-based structural health monitoring as a compact alternative to microphone-assisted Fast Fourier Transform (FFT) analysis during the milling of Al-7075-T6. Experiments were conducted with a constant axial depth of cut of 0.5 mm while feed rate (50–70 mm/min) and spindle speed (1200–4300 rpm) were varied. A surface-bonded piezoelectric sensor recorded impedance signatures simultaneously with acoustic data. Dominant modes detected by EMIS lay between 90 Hz and 1.5 kHz and coincided with FFT peaks. The discrepancy between the two methods remained within 1.54–10.78%. The close agreement indicates that a single EMIS sensor can provide reliable, operator-independent vibration diagnostics without the extensive signal-conditioning infrastructure required by microphones. EMIS offers a pathway for real-time, closed-loop vibration control in milling applications.

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Advanced Engineering Forum Vol. 59 View Preview

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Periodical:

Advanced Engineering Forum (Volume 59)

Pages:

23-32

DOI:

https://doi.org/10.4028/p-H0ti45

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Online since:

June 2026

Authors:

Gökhan Haydarlar, Mehmet Alper Sofuoğlu*, Mesut Tekkalmaz

Keywords:

Al-7075-T6, Electromechanical Impedance Spectroscopy (EMIS), Milling Vibration Diagnostics, Structural Health Monitoring, Vibration Suppression

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© 2026 Trans Tech Publications Ltd. All Rights Reserved

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