Force-based model for tool wear monitoring in face milling

Abstract One of the most important techniques for automation which should be developed at current stage is on-line tool wear monitoring technique. In this paper, an on-line tool wear monitoring approach for face milling process is proposed. This approach uses the relationship between flank wear and average cutting force coefficients to estimate tool wear. The relationship between flank wear and average cutting force coefficients is established based on data obtained from a series of experiments. It is found that tool wear can be properly estimated by knowing the average cutting force coefficients and cutting parameters when fly cutting aluminum with a single cutter and workpiece geometry.