Tool Monitoring Systems

In the case of tool monitoring systems, the tool has to be continuously monitored while it is cutting. This would allow for continuously looking for tool wear, as well as the times when the tool breaks because of unforeseen conditions in the machining system. The various methods adopted for these two functions are slightly different.

1. Tool Wear Monitoring - Tool wear is a phenomenon whose behaviour can be described qualitatively but not quantitatively. Hence some tool life equations do exist, their universal adaptability or their use even in restricted work-tool material zones for all parameter ranges are doubtful. Further, direct in-process measurement of tool wear is difficult in view of the location of the wear and the measurement techniques used.

2. Tool Breakage Monitoring -Another problem frequently faced is the breakage of tool during cutting that if not detected in time may lead to several problems related with spoiled jobs, specifically in unmanned machining shifts. Therefore it is necessary to have systems that can detect the breakage of tools by some means and give an alarm to the operator, or automatically replace the tool through a sister tool from the secondary tool storage.