Real-time tool wear monitoring is an important technique need to be developed to fulfill the demand from the fast development in machining industry. This paper proposed a new method of online tool wear monitoring using portable digital assistant (PDA)-based device to monitor progression of flank wear land during turning process by on-line detecting and analyzing the machining force signals. The machining tests were carried out on turning machine, and Kistler 9255B dynamometer was used to measure the cutting force signal, which was amplified and displayed in the DasyLab software. The measured cutting force signals stored in Dasylab was then analyzed using I-kaz 3D. The analysis was successfully done using newly developed program, C++ language and Visual Basic embedded to display the result on the PDA. This new developed program was installed on PDA to monitor the tool flank wear progression by three modes of different color which include: green (good condition), yellow (transition zone) and red (end of cutting). Therefore, it gives early warning related to the damage and failure of cutting tool, consequently helps the operation of machine to be smoothly operated in order to produce an acceptable quality in manufacturing process.
Key words: Real time monitoring, tool flank wear, I-kaz 3D, cutting force signal, portable digital assistant (PDA).
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