In-process toolwear detection of uncoated square end mill based on electrical contact resistance

This paper presents a method for in-process detection of tool wear in square end mills. The developed highspeed tool wear detection system uses the contact resistance between the tool and workpiece as a gauge to monitor the progression of tool wear. The electrical resistance decreases with an increase in contact area on the tool flank. In the experiments conducted in our previous study, the target was the face milling process. In the present study, the experiments were conducted on down cut milling with a square end mill. The results are presented based on the observations made on the relationship between the area of tool flank wear and tool-work contact resistance. In conclusion, the results of the experiment show that the present tool wear detection system is effective as an in-process tool wear detection system for square end mills.