Geometrical quality like surface roughness and accuracy of form has been very important in ultra-precision machining. However, because of improvement of quality of finished surface with progress of ultra-precision machining technology, quality of subsurface material like affected layer also becomes important lately. In ultra-precision cutting tool wear is serious problem since tool wear fairly affects surface integrity of machined part. However it is difficult to directly detect tool wear on machine since the tool wear affecting surface integrity is extremely small. Therefore the purpose of this study is to find out effective parameters obtained during cutting to detect single crystal diamond tool wear in ultra-precision cutting of aluminum alloy. Wear of cutting edge with large nose radius was observed by a scanning electromicroscope. Cutting forces and AE signals during cutting were also measured to calculate values of the parameters from them. As a result of cutting tests and considerations, it was concluded that area of flank wear land can be related with static and dynamic components of cutting forces and area of rake wear land can be related with RMS values of AE signals.
