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

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. © 2004 Elsevier Ltd. All rights reserved.