Microcontroller Based Tool Wear Monitoring during End Milling of Hardened Steel

In the world of machining, cutting force is considered to be the important variable that best describes the cutting process. The cutting force signal provides rich information for tool wear in end milling operation, hence is considered for tool condition monitoring system. From experimental tests in end milling on AISI-D2 steel, it has been found that the flank wear is the prominent wear under normal cutting conditions. Hence, the standard criterion that determines significant flank wear of an end mill is used to set the corresponding threshold values for the cutting force signal in the tool condition monitoring system. The resulting complex variations of the cutting force attempts to correlate the tool wear with the measured force signal. The primary objective of this research is to monitor tool wear during end milling of AISI-D2 steel, using a cost-effective microcontroller. The results of the tool wear on the end mill cutter; with and without tool condition monitoring system have been analyzed.

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