Tool Life Detecting System for Milling Cutter using Damage Sensor Integrated Insert – Influence of Number of Damaged Inserts on machined surface

Abstract

Influence of damaged inserts on machined surface in face milling was investigated in order to apply the developed tool–life–detecting system to multi points cutting. The theoretical maximum height of machined surface was derived when face milling with inserts that have a corner radius and some location error. Surface roughness increased with an increase of damaged insets. The roughness depends largely on axial run out of inserts when milling at small feed or when one of inserts was broken. The tool–life–detecting system should detect the brakeage of two successive inserts in order to keep surface quality. A possible circuit composed of damage–sensor integrated inserts were also proposed.