A study on a throw away tool equipped with a sensor to detect flank wear.

In order to automate tool management, which is a serious problem in a flexible manufacturing system, a cutting tool equipped with a sensor to detect flank wear and tool failure was developed. The sensor is a resistance film circuit formed from titanium on the flanks of a throw away alumina tip. The sensor is located in a position parallel with the cutting edge. The wear of the tool is detected by measuring electrical resistance. The electrical resistance of the sensor gradually increases as the resistance film circuit is worn off by flank wear and the circuit becomes narrower. Flank wear can therefore be directly detected by measuring the electrical resistance of the sensor. In the experimental results, close agreement between measured and calculated values was obtained, and it was clear that flank wear could be detected by measuring the electrical resistance of the sensor after each use.