Tool condition monitoring (TCM) systems can improve productivity and ensureworkpiece quality, yet, there is a lack of reliable TCM solutions forsmall-batch or one-off manufacturing of industrial parts. TCM methods whichinclude the characteristics of the cut seem to be particularly suitable forthese demanding applications. In the first section of this paper, threeprocess-based indicators have been retrieved from literature dealing with TCM.They are analysed using a cutting force model and experiments are carried outin industrial conditions. Specific transient cuttings encountered during themachining of the test part reveal the indicators to be unreliable.Consequently, in the second section, a versatile in-process monitoring methodis suggested. Based on experiments carried out under a range of differentcutting conditions, an adequate indicator is proposed: the relative radialeccentricity of the cutters is estimated at each instant and characterizes thetool state. It is then compared with the previous tool state in order to detectcutter breakage or chipping. Lastly, the new approach is shown to be reliablewhen implemented during the machining of the test part.
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