Although a wide variety of tool failure sensing techniques have been developed over the years, few of them have been used in industries successfully. This paper provides a review of the numerous techniques and methods of monitoring tool wear particularly in turning operations. By and large, these techniques appear to be “single-minded” in that they are capable of detecting and diagnosing tool wear and failure relating to particular classes of faults. A universal approach which can detect the very many failure modes in tool condition monitoring has still not been devised.

Tool wear and failure monitoring techniques for turning—A review

Cutting force-based real-time estimation of tool wear in face milling using a combination of signal processing techniques

Non-linear regression analysis techniques are used to establish models for wear and tool life determination in terms of the variation of a ratio of force components acting at the tool tip. The ratio of the thrust component of force to the power, or vertical, force component has been used to develop models for (i) its initial value as a function of feed, (ii) wear, and (iii) tool lifetimes. Predictions of the latter model have been compared with the results of experiments, and with predictions of an extended Taylor model. In all cases, good predictive capability of the model has been demonstrated. It is argued that the models are suitable for use in adaptive control strategies for centre lathe turning.

Tool life determination based on the measurement of wear and tool force ratio variation

Modelling of tool wear based on cutting forces in turning

Relationship between tool flank wear area and component forces in single point turning

Automatic in-process detection of the condition of the cutting tool is an important capability required in unmanned machining. This paper describes the use of multi-component force measurements for the purpose of tool condition monitoring during adaptively-controlled metal-cutting on a turret lathe.

Tool Condition Monitoring Using Multi-Component Force Measurements

This paper considers the design, implementation and testing of a multi-component force transducer for a turret lathe. The system developed, using a dynamometer and strain gauges, permits measurement of the three components of cutting force in turning operations and of torque in drilling operations. The dynamometer has been designed as an integral part of the coupling between the turret and the machine, and to be capable of operating in a machine shop environment.

G. E. Wilson

Papers

Tool Condition Monitoring Using Multi-Component Force Measurements

A Force Transducer for a Turret Lathe