The optimization in the machining process has been a long standing goal of the manufacturing community. The optimization is composed of two main subject; one is to select an optimum cutting condition, and the other is to detect the emergency situation and take necessary actions in real time base.
This paper proposes a realiable and practical guide system whose purpose is the optimization of cutting conditions, and the detection of tool failure in the machining process. The optimal cutting conditions are searched through the estimation of tool wear rate and the establishment of accessible field from the measured cutting temperature and force. Tool breakage is detected by the normal force component acting on minor flank face extracted from on-line sensed feed force and radial force.
In experiments, the proposed guide system has proved availability for the decision of reliable cutting conditions for the given tool-work system and the detection of tool breakage in
