Novel tool wear monitoring method in ultra-precision raster milling using cutting chips

Guoqing Zhang, Suet To, Gaobo Xiao

Research output: Journal article publicationJournal articleAcademic researchpeer-review

35 Citations (Scopus)


Tool wear monitoring is a popular research topic in the field of ultra-precision machining. However, there appears to have been no research on the monitoring of tool wear in ultra-precision raster milling (UPRM) by using cutting chips. In the present research, monitoring tool wear was firstly conducted in UPRM by using cutting chips. During the cutting process, the fracture wear of the diamond tool is directly imprinted on the cutting chip surface as a group of 'ridges'. Through inspection of the locations, cross-sectional shape of these ridges by a 3D scanning electron microscope, the virtual cutting edge of the diamond tool under fracture wear is built up. A mathematical model was established to predict the virtual cutting edge with two geometric elements: semi-circle and isosceles triangle used to approximate the cross-sectional shape of ridges. Since the theoretical prediction of cutting edge profile concurs with the inspected one, the proposed tool wear monitoring method is found to be effective.
Original languageEnglish
Pages (from-to)555-560
Number of pages6
JournalPrecision Engineering
Issue number3
Publication statusPublished - 1 Jan 2014


  • Cutting chips
  • Monitoring
  • Tool wear
  • Ultra-precision raster milling
  • Virtual cutting edge

ASJC Scopus subject areas

  • Engineering(all)

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