A Review on Tool Flank Wear Monitoring by Tool Condition Monitoring System using Various Approaches

Abstract

Increasing demands of process automation for un-manned manufacturing attracted many researchers in the field of on-line
monitoring of machining processes. In view of this, extensive research work is taking place world-wide in the area of on-line tool
condition monitoring system. Tool wear is the most undesirable characteristic of machining processes as it adversely affects the
tool life, which is of foremost importance in metal cutting owing to its direct impact on the surface quality of the machined surface,
and its dimensional accuracy, and consequently, the economics of machining operations. Tool wear has negative effects on
surface quality, dimensional precision of work piece, and may even cause a harmful effect on safe operation of total
machining system. According to the research, about 20% machine downtime is caused by the tool wear. In addition, the
cost of cutting tool and tool changing is about 3–12% of the total machining cost and method for on-machine tool
progressive monitoring of tool flank wear by processing the turned component. Therefore, methods for cutting tool wear in an over
view of the maximum use of cutting tools. With an effective monitoring system, the wear and damages to the machine tool,
downtime, lead time and scrapped components can be avoided. This paper provides brief overview on tool condition monitoring.