This paper presents the instrumentation of a fine blanking tool with acoustic emission and force sensors for the aim of condition monitoring. Due to the lack of suitable force sensors, a new strain gauge based force sensor was developed. All required step to a functional sensor are presented including the design with Finite Element Analysis, the sensor instrumentation and the calibration. For an efficient processing, the signals are portioned into cutting operation and auxiliary motions. To identify anomalous behavior, each cutting operation is analyzed using the central moments mean, variance, skewness and kurtosis. The cutting operations are also represented as Time Histogram to deal with anomalies not covered by the central moments. An exemplary analysis is show for the acoustic emission signals.
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