Evaluating tool wear by measuring the real-time contact resistance

  • Chuang-Wen YaoEmail author
  • T. W. Hong


A method is proposed to diagnose wear and to determine the replacement schedule for a working end-mill cutter. Changes in the contact area between a working end-mill cutter and the workpiece during a milling process lead to a real-time variation in the contact resistance. Measuring the real-time contact resistance using a micro-ohm meter and a GPIB (general-purpose interface bus) interface control card allows the wear in a working end-mill cutter to be determined. Real-time contact resistance values for a working end-mill cutter are measured and recorded every second. The experimental results demonstrate that when the milling cutter operates continuously for about 20,000 s, the contact resistance decreases to about 25% of the original value for the brand new state. This method can be used for the future design of milling machines. If the value of the contact resistance for a working end-mill of the same type approaches this value, the cutter should be replaced in order to maintain efficient machining.


Contact resistance Tool wear Contact area End-mill cutter 


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© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  1. 1.Department of Mold and Die EngineeringNational Kaohsiung University of Science and TechnologyKaohsiung CityTaiwan

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