Use of process signals for tool wear progression sensing in drilling small deep holes

Detailed knowledge about the relation between wear progression of a cutting tool and the cutting forces generated is of paramount importance for the development of a tool condition monitoring strategy. This paper discusses the changes in the different process signals with progressing tool wear of small diameter twist drills (D=1.5 mm), when drilling boreholes having a depth of 10 times the diameter in plain carbon steel using MQL. The effect of different wear patterns on the process signals is presented. Furthermore, several features, which evolve over the life of the drills, are identified and extracted from the process signals. Knowledge about the evolution of these features can support the user to determine the final tool life stage, so that the drill can be replaced before the final fracture occurs.