Date of Award

Winter 2008

Project Type


Program or Major

Mechanical Engineering

Degree Name

Master of Science

First Advisor

Robert Jerard


This study establishes a way to monitor tool wear in end milling using a tangential force model coefficient method. An experimental investigation of the characteristics of tangential force model coefficients, KTC and KTE, under different cutting conditions is presented. Experimental results indicate that the coefficients are relatively insensitive to the cutting conditions and quite sensitive to tool wear. Several tool wear experiments were performed on AISI 1018 steel. The tool wear was examined using an optical measurement inspection system. The results indicate that KTE increases proportionally with tool flank wear while K TC stays relatively constant until close to the end of tool life. Other possible wear indicators were studied, specifically the radial coefficients (KRC & KRE) and vibration signals. It was found that KRC & KRE are proportional to KTC & KTE, and the vibration signal magnitude is related to flank wear.