Introduction. Due to a significant number of factors affecting the change in the properties of a dynamic system, excessively conservative processing conditions are chosen to ensure the high quality of the resulting product. This limits the efficiency of the process and leads to an increase in the cost of production. Accordingly, modern approaches are needed that will allow diagnosing the current state of processing and making timely decisions to replace the tool, correct or change the control program. The significance of the ongoing research is to propose a real-time monitoring approach to milling control to identify emerging processing errors, predict potential problems and improve uptime. Subject. The paper discusses the features of the real-time monitoring system during mechanical processing with a single- and double-edge cutting tool, taking into account acoustic wave filtering, minimizing surface roughness. The purpose of the work is to determine the effect of the inclination orientation of the ball-end tool on the surface roughness value using real-time monitoring during milling on CNC process equipment. Methods. The study provides methods of correlation and regression analysis. The calculated data were obtained by means of vibroacoustic diagnostics and measured in the range of values of the variable angle of inclination of the surface for single- and double-edge cutting tool based on the provisions of the theory of oscillations and vibroacoustic diagnostics, cutting theory, digital processing and digital filtering of signals. Results and discussions. Experimental data obtained during machining made it possible to determine that an increase in the angle of inclination of a single-edge cutting tool has practically no effect on the change in the amplitude parameters of roughness. The values of vibroacoustic diagnostics and roughness, when using a double-edge ball-end tool, show a consistent picture with the effects created by the angles of inclination and advance. The obtained solutions to the problems of monitoring and analyzing the roughness parameters can significantly reduce the amount of experimental research and clarify the idea of the practical implementation of the method of acoustic monitoring of the cutting process.

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Introduction. Domestic and foreign works on the milling of complex-profile surfaces with a ball-end tool were analyzed. Methods of surface quality control and ways to provide amplitude parameters of roughness, based on research data and field experiments, were considered. Theoretical provisions on the determination of cutting forces and the results of vibroacoustic diagnostics were presented.Materials and Methods. The methods of correlation analysis, comparison and generalization of the results were applied. The data were calculated at different tool angles, taking into account the instantaneous cutting forces, and were fixed in the range of values of the variable feed per tooth (fz) and the angle of inclination of the surface (γ). The vibroacoustic diagnostic data and theoretical data of the presented model at different tool inclination angles were verified by experiment. Consequently, such methods can be used to predict surface roughness parameters.Results. The relationship between cutting forces, tool inclination angle, and vibroacoustic diagnostics data was found. A model of the cutting force and tool displacements was formulated taking into account the inclination of the surface. The optimal range of the inclination angle of the tool to the surface to be machined, at which the minimum values of the amplitude parameters of roughness were achieved, was determined. The sound vibrations obtained empirically, presented in spectral and wave forms, were in good agreement with data from other sources. This allowed us to conclude about the feasibility of forecasting and monitoring roughness parameters in real time through acoustics.Discussion and Conclusions. It was established that the growth of forces in the direction ae(X) and fz(Y) was observed at γ > 40°. This was due to the distribution of the components of the cutting force along the cutting edge and depended on the inclination of the surface. The amplitude parameters decreased when the angle increased from 10 to 40 degrees. The found interrelations of force analysis, processing directions, and vibroacoustic diagnostics have validated the use of vibroacoustic diagnostics to predict surface roughness. Acoustic diagnostics, regardless of the layout of technological equipment, enables to quickly adjust the sound device and assess the impact of cutting modes on roughness parameters.

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