In-process tool wear estimation in milling using cutting force model

Abstract Reliable tool wear monitoring technique is one of the important aspects for achieving an integrated and self-adjusting manufacturing system. In this paper, a tool wear estimation approach for milling is proposed. This approach uses the relationship between flank wear and the average tangential cutting force coefficient to estimate tool wear. A series of experiments were conducted by designing experimental techniques to determine the relationship between flank wear and tangential cutting force coefficient as well as cutting parameters such as cutting speed, depth of cut and feed per tooth. Additional tests were conducted to check the feasibility of the model. Comparison between the proposed model performance and the one established earlier has shown that the proposed model predicts tool wear with higher accuracy.

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