On the correlation between dynamic cutting force and tool wear

Abstract The dynamic component of the cutting force has so far received little attention as a possible parameter for tool wear and tool failure monitoring. Analysis of the frequency spectrum shows a distinct peak frequency which is consistent for a wide range of machining conditions and for different lathes. The peak frequency source has been identified as being due to the natural frequency of the vibrating tool holder rather than oscillations arising from the chip formation process. Good correlation is found between the dynamic cutting force and flank wear. The dynamic force falls rapidly before the entry into the tertiary zone as well as prior to the onset of catastrophic tool failure.