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<p>This study presents a continuous tool wear evaluation framework by integrating ultrasonic contact area measurement with the Taylor tool life model in milling operations. Unlike conventional wear assessment approaches based on flank wear width or indirect sensing signals, the proposed method directly quantifies the evolution of the real tool–workpiece contact interface during machining. Experimental results demonstrate that the contact area increased continuously with machining time under all cutting conditions. Under the higher cutting speed condition (V<sub>C</sub> = 49.35&#xa0;m/min), the contact area increased from 12.54&#xa0;mm² to 49.21&#xa0;mm² after 600&#xa0;min of machining, corresponding to an increase of approximately 292.4%. In contrast, the lower cutting speed condition (V<sub>C</sub> = 45.24&#xa0;m/min) resulted in a final contact area of 35.25&#xa0;mm², which was approximately 28.4% lower than that obtained at the higher cutting speed. By incorporating the measured contact area into the Taylor tool life equation, the wear exponent was determined as <i>n</i> ≈ 0.09, which agrees well with the typical range reported for high-speed steel tools. Furthermore, a critical contact area threshold of approximately 35&#xa0;mm² was identified as the transition from steady-state wear to accelerated wear, indicating the onset of severe tribological and thermal deterioration at the tool–workpiece interface. The proposed approach provides a quantitative and non-destructive method for continuous tool condition monitoring and predictive tool life evaluation. The successful integration of ultrasonic sensing with tool life modeling demonstrates strong potential for real-time machining diagnostics and intelligent tool replacement applications.</p>

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Real-time milling tool wear prediction using ultrasonic contact interface measurement and taylor tool life modeling

  • 期刊论文

  • 发表日期：

    2026年6月26日

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  • Kuan-Nien Yao,
  • Yiin-Kuen Fuh

摘要

This study presents a continuous tool wear evaluation framework by integrating ultrasonic contact area measurement with the Taylor tool life model in milling operations. Unlike conventional wear assessment approaches based on flank wear width or indirect sensing signals, the proposed method directly quantifies the evolution of the real tool–workpiece contact interface during machining. Experimental results demonstrate that the contact area increased continuously with machining time under all cutting conditions. Under the higher cutting speed condition (VC = 49.35 m/min), the contact area increased from 12.54 mm² to 49.21 mm² after 600 min of machining, corresponding to an increase of approximately 292.4%. In contrast, the lower cutting speed condition (VC = 45.24 m/min) resulted in a final contact area of 35.25 mm², which was approximately 28.4% lower than that obtained at the higher cutting speed. By incorporating the measured contact area into the Taylor tool life equation, the wear exponent was determined as n ≈ 0.09, which agrees well with the typical range reported for high-speed steel tools. Furthermore, a critical contact area threshold of approximately 35 mm² was identified as the transition from steady-state wear to accelerated wear, indicating the onset of severe tribological and thermal deterioration at the tool–workpiece interface. The proposed approach provides a quantitative and non-destructive method for continuous tool condition monitoring and predictive tool life evaluation. The successful integration of ultrasonic sensing with tool life modeling demonstrates strong potential for real-time machining diagnostics and intelligent tool replacement applications.