An online approach for power consumption monitoring of tool condition

The major goal of this study is to create an accurate approach for tool flank wear prediction using the tool force signal during mild steel cylindrical blind hole end mill machining. Low-cost spindle current sensing technology is one of the most popular methods of predicting tool wear by measuring spindle power consumption in CNC machines and correlating power growth to tool wear. This paper presents a method for monitoring tool condition based on cutting power measurement. The findings demonstrate the accuracy of this method and the ability to greatly improve comprehension of the overall connection between cutting power and tool wear. A sharp instrument also required less power than one that was used or worn. Due to having to overcome the increased friction force on the cutting contact area, power consumption rises as tool wear does. Additionally, increasing the cutter diameter results in a higher power requirement. Also, the results showed that when the flank wear reaches up to 0.15 mm, the time required to fail the tool decreases by 67% with an increase in the energy consumed by 20%.