Tool Wear and Breakage Detection Using a Process Model

On-line sensing of tool wear and breakage In machining has been a long standing goal of the manufacturing community. Wear and breakage detection systems are typically based on force, acoustic emission, current or temperature measurement. They are Important for reliable unmaνed operation, and also for implementation of an adaptive control optimization system. This paper proposes a model-based approach to on-line tool wear and breakage detection under varying cutting conditions based on force measurement. The proposed model is used together with on-line parameter estimation to track flank wear during cutting. The proposed method is illustrated with a simulation study, the results of which confirm the feasibility of the model-based approach.

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