A Novel Tool Condition Monitoring Technique of Determining Insert Flank Wear Width of Indexable Face Milling Tools Using On-Machine Laser Tool Setters

Tao Fang ^1,2, Zezhong Chen ³, Haibo Feng ⁴

⁰Department of Mechanical Engineering, Northwestern Polytechnical University, Xi'an 710072, China.

Micromachines +

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October 29, 2025

View abstract on PubMed

Summary

Smart machining uses laser tool setters for tool wear compensation. A new method calculates insert flank wear width using on-machine laser tool setters, improving tool life and preventing premature replacement.

Area Of Science

Manufacturing Engineering
Materials Science

Background

Indexable face milling tools experience rapid insert wear due to large depth of cuts.
Current smart machining relies on tool wear compensation and condition monitoring, but on-machine laser tool setters lack flank wear measurement capabilities.
This leads to suboptimal tool replacement, either too early or too late.

Purpose Of The Study

To propose a novel technique for determining insert flank wear width of indexable face milling tools using on-machine laser tool setters.
To enable accurate tool condition monitoring and optimize insert replacement timing.

Main Methods

Developing a calculation method for insert flank wear width based on insert geometry, worn cutting edge, and a new milling mechanism.
Measuring insert radius wear with an on-machine laser tool setter.
Calculating flank wear width to assess tool condition against a failure threshold.

Main Results

The optimal measurement height for radius wear was identified near specific geometric points (MR3 and MR5).
A wear land width threshold of 0.10 mm was established for tool failure.
The proposed calculation method achieved high accuracy with errors within 14.00%.

Conclusions

The novel technique accurately determines insert flank wear width using existing on-machine laser tool setters.
This enables effective tool condition monitoring, maximizing insert lifespan and preventing premature or delayed replacements.
The method is verified and ready for industrial application in machining.

Keywords:

on-machine tool measurement smart machining tool flank wear width tool radius measurement tool replacement