The loudest CNC vibration axis was not the most useful one
was looking through accelerometer data from CNC milling runs, comparing good and bad toolpaths.
The Z-axis looked like the obvious channel to monitor because it had the highest vibration energy. But in bad runs, its RMS only moved from about 1024 to 1081. That is roughly a 5% increase.
The Y-axis told a much clearer story. Healthy RMS was around 195, but bad runs jumped to about 305. That is a 56% spike on the axis you might ignore because the numbers look smaller.
Kurtosis was even more useful. In good runs, X and Y were around 6.5. In bad runs, they dropped closer to 3.5. So the failure was not just "more vibration". The vibration pattern changed.
Main takeaway: do not just watch the loudest axis.
For this run, Y-axis RMS and kurtosis were better signals than raw Z-axis energy. Also, thresholds need to move over time as the machine wears. Static models will age badly.