Researches on tool wear progress in mill-grinding based on the cutting force and acceleration signal

Tool wear progression has greatly impact on the machining quality, tool wear evaluation is useful to obtain tool states. Mill-grinding experiments are performed using the electroplated diamond tool to reveal tool wear progression. Both time and frequency domain, dimensional and dimensionless characteristics of cutting force and acceleration signals are analysed. Among time domain characteristics, peak and average values exhibit low and stable amplitudes at the initial wear stage, and evolve to large and fluctuant amplitudes at the severe wear stage. For frequency domain analysis, gravity frequency exhibits a decrease trend with tool wear progression. Among dimensionless characteristics, kurtosis and margin factors show a maximum value when tool wear progression goes into the severe wear stage, and can be applied to evaluate tool wear progression. Tool wear modes include the wearing flat process and fracture of diamond grains, tool wear mechanisms include the abrasive wear, adhesive wear and grain fracture.