In the first part of the presented work the results of research regarding integration of acoustic emission sensor technology during the machining of material compounds will be depicted. Extruded aluminium alloys (AW6060) provide as a matrix material, while functional elements in form of conductive paths and reinforcing elements (1.4310) are embedded. The aim of this research is to detect material transitions precisely and to generate an automatable process controlling. To analyse the acoustic emission signals a real-time capable system is used. The frequency spectrum as well as the root mean square-value will be depicted for the experiments. The second part of the work outlines the development and testing of an automated modal impact hammer to provide an impulse based structural excitation source for experimental modal analysis. The use of this pendulum is to increase the repeatability, to enable the variability of the excitation force and to prevent so called double hits. Therefore it is well suited for frequency response measurements of tools. With these measured data, stability charts can be simulated in further steps. With this the milling tool can be used in the optimum range of parameters.