Tool wear estimation under a strategy for constant cutting forces in end willing

This paper describes the process and utility of a method to detect cuffing forces and estimate tool wear with inner sensors using a linear motor driven machining center (MC). This method is intended to realize an intelligent end-milling system. First, a mathematical prediction model for cutting forces in end milling was extended to handle cases with worn end mills. Cutting experiments using a linear motor driven MC with a static guideway showed that monitoring cutting forces and estimating tool life by utilizing the current of a feed motor were very effective without having to use the current of a spindle motor In addition, we designed algorithms which allow the feed rate to change automatically according to the current of a feed motor Thereby, these algorithms can maintain constant cutting forces. Experimental results using them revealed that tool life increased by restraining the progress of tool wear Using both the mathematical prediction model and the inner sensor based on the feed motor current, one can estimate how far the tool wear progresses if the cutting engagement angle is given as a known quantity.