Materials Today: Proceedings xxx (xxxx) xxx

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Materials Today: Proceedings

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Indirect method of tool wear measurement and prediction using ANN

network in machining process
P.J. Bagga, M.A. Makhesana ⇑, H.D. Patel, K.M. Patel
Mechanical Engineering Department, Institute of Technology, Nirma University, Ahmedabad 382481, India

a r t i c l e i n f o a b s t r a c t

Article history: In the present scenario, ensuring the quality of products is a major factor in the metal cutting industries
Received 5 November 2020 and it demonstrates an overall success factor for businesses. Tool wear is one of the major factors which
Received in revised form 19 November 2020 affect the quality of the product, production time, and also the manufacturing expenses in the metal cut-
Accepted 26 November 2020
ting industry. The indirect method for tool condition monitoring system is very important for the increas-
Available online xxxx
ing requirements of cost reduction and quality management in modern manufacturing industries. The
indirect method of determining tool wear using Artificial Neural Network (ANN) has been proposed by
Keywords:
evaluating force and vibration during dry turning. For the experiments, the cemented carbide insert
Indirect method
Tool wear
and EN-8 (medium carbon steel) is utilized as workpiece material. Total nine experimental runs based
Cutting force on the Taguchi L9 orthogonal array are conducted. Cutting speed, feed, and depth of cut is selected as
Vibration signal machining parameters. Both vibration signal and cutting force measured during machining by measuring
Image processing devices and its measured signal stored in the data acquisition system. The validity of the data used to pre-
Machine vision dict the tool wear using the ANN model has been assessed by comparing with the manual measurement
of tool wear. It has been found close co-relation between the predicted and measures tool wear during
the machining. The study proves that the ANN is capable of predicting tool wear in machining for the con-
sidered machining parameters.
Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Confer-
ence on Materials, Processing & Characterization.

1. Introduction and background
Nowadays, a high-speed numeric controls machine tool fre-
quently used in the manufacturing sector that requires the uses
of the computers to power machine tools including lathes, mills,
grinders, etc. It obtained great deal attention due to its high accu-
racy and precision work during the machining process. Moreover,
there are other concerns related to the deterioration of the quality
of the product owing to the continued usage of worn-out tools and
the rise in the price of the product due to increasing rework as a
result of earlier predictive machine tool maintenance system is
required in advance machine tool manufacturing sector and
Throughout the metal cutting industrial the price of manufacturing
products and maintenance time is increased and production time
decreased due to the failure of a cutting tool so that tool condition
monitoring system work as a predictive maintenance system is
required to limit machine downtime and increase productivity.
⇑ Corresponding author.
E-mail address: mayur.makhesana@nirmauni.ac.in (M.A. Makhesana).
The contact between the tool, workpiece, and chip causes the tool
shape to change this process known as tool wear. During machin-
ing, the cutting edges of a tool gradually wear out so that in time
the tool ceases to cut efficiently or may even fail. Machining with
worn tools leads to increased tool forces, higher interface temper-
ature, poorer surface finish, less accurate dimensions, and noisier
cutting action [1]. When the wear reaches a certain stage the tool
must be reground or replaced by a new tool if machining is to be
continued satisfactorily. It is also possible to predict tool wear
levels based on test data or physical considerations. Wear on the
tool is observed in two places: on the tool flank called flank wear
and on the rake face called crater wear. Flank wear is characterized
by the formation of a wear land on the tool face while wear on the
rake face generally appears as a crater. Flank wear is caused by the
rubbing of the flank surface of the tool with the newly cut surface
of the workpiece. The extent of flank wear depends upon the rela-
tive hardness of the tool and workpiece materials. The wear land is
not generally uniform along the full cutting edge length. Some of
the patterns of flank wear shown in Fig. 1. If the wear profile is uni-
form, the typical wear land width value is determined and the tool

https://doi.org/10.1016/j.matpr.2020.11.770
2214-7853/Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Materials, Processing & Characterization.

Please cite this article as: P.J. Bagga, M.A. Makhesana, H.D. Patel et al., Indirect method of tool wear measurement and prediction using ANN network in
machining process, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.11.770
P.J. Bagga, M.A. Makhesana, H.D. Patel et al.
Fig. 1. Pattern of tool wear [3].
should be used where the wear width is smaller than and equiva-
lent to 0.3 mm and in the case of irregular wearing pattern, the
average surface width of the groove must be taken as the tool life
standard and the limit should be 0.6 mm [2].
Crater wear occurs on the rake face of the cutting tool at a short
distance away from the cutting edges. Crater wear mechanism
occurs due to diffusion of metal as such the rate of wear depends
upon the tool chip interface temperature and the metallurgical
relationship between the tool and work pair. Since the tool chip
interface temperature is maximum at a short distance away from
the cutting edge crater wear is maximum at that point. Large crater
depth is not desirable and the tool must be reground or replace
before such large crater leads to failure of the tool. As cutting is
continued the crater increase in size till of the tool between the
crater and flank wear land becomes so weak that it breaks down
suddenly. Notch wear is a special form of integrated flank and rake
face wear that occurs adjacent to the point where the main cutting
edge intersects the work surface. When the nose of the tool is
rough, abrasion, and friction between the tool and workpiece will
be high. More heat will be generated under these conditions and
cutting forces may also be higher.
1.1. Tool condition monitoring system
According to the rising need to reduce production costs under
market competition, unchecked machining is a core component
of most manufacturing industries. Moreover most of the costs
related to larger failure arising from wear of tool. In time, worn
tools can be replaced by the use of flank wear identification meth-
ods in the tool condition monitoring system (TCMS). The different
functions that the accurate TCMS needs to perform can include
analysing tool wear, detecting tool breakage, checking cutting tem-
perature, surface finish, machine noise, and workpiece size. Main
functions performed by a successful TCMS include signal acquisi-
tion, signal pre-processing, feature selection, and decision making.
A TCM system consists of two-part: the first one is a hardware part
and the second one is a software part. Signal or data acquisition is
only included in the hardware part and the rest of things like signal
pre-processing, signal interpretation, and the state of tool predic-
tion come under the software part. Data collection methods for
determining flank wear can be categorized as direct and indirect
methods [4]. The direct methods are change of the tool geometry
2
Materials Today: Proceedings xxx (xxxx) xxx
measurement using a digital electrical microscope, weights mea-
surement of a tool, visual inspection, electrical techniques, radioac-
tive techniques, analysis of wear practical on chips, etc. whereas
indirect methods are based on parameter measured such as cutting
force, vibration, sound, temperature, surface roughness, etc. during
the cutting operation that can be correlated to wear state.
Hesser and Frank [5] developed experiment set up and analysed
the programmable sensor data for online monitoring of tool wear
state and also made tool life prediction with the help of retrofitting
techniques applied on older CNC milling machine tool. The pro-
grammable sensor Bosch XDK was built-in with accelerometer
BMA280. The vibration signal during the machining was measured.
The authors had analysed the stored sensor data of vibration signal
pattern with the help of ANN (artificial neural network) by given
constant process parameters like feed, doc, cutting speed, and
length of cut on steel block. The authors had considered two end
milling cutting tools with different wear conditions. The trained
ANN was classifying the tool state during the machining process
and plots the tool wear condition and store on the computer. Kene
et al. [6] gave analytical modeling of tool health monitoring system
using multiple sensor data fusion approach. Experiments were per-
formed on EN24 hardened steel on CNC Turning machine tool in
which the machine tool attached sensors like accelerometer,
dynamometer, acoustic emission, and thermocouple and the cut-
ting tool was used uncoated carbide tool. The experiment were
designed based on DOE. Authors have investigated the sensor
fusion approach compare with a single sensor fusion-based
approach and got a better result tool wear monitoring system.
The comparison of calculated tool wear and predicted tool wear
based on the approach revealed the percentage error 8.45%.
Malghan et al. [7] explained the indirect approach to find cut-
ting force based on power consumption on a particular axis during
the face milling operation via Ethernet cable. The authors per-
formed experiments on CNC vertical milling machine and design
the experiment trial based on the ANOVA method on AA6061 alu-
minum alloy. The objective was to optimizing surface roughness
and prediction surface quality applied different process parameters
from the indirect measurement of force calculation in a particular
direction. It was concluded that higher surface roughness detected
based on the greater axial movement of axial feed rate. Niu et al.
[8] developed an experimental set up for tool wear monitoring
modal for two vertical CNC milling machine tools of titanium alloy.
P.J. Bagga, M.A. Makhesana, H.D. Patel et al.
Two different diameter cemented carbide milling tools were used
in the tool life tests. Same process parameter for both machine
tools were used as the fixed depth of cut, cutting speed, length of
cut in down milling condition, and feed rate. Multiple sensors were
utilized for tool wear monitoring as a dynamometer sensor,
accelerometer sensor, and microphone and the original sensor sig-
nal was analysed by using time domain, frequency domain, time,
and frequency domain feature extraction tool during cutting oper-
ation. Support vector machine was used to identify wear stage of
cutting tool and compared with direct measurement tool wear.
The presented approach resulted in 96.7% accuracy.
Aghdam et al. [9] studied the connection between the vibra-
tional features of the tool/holder assembly and the tool’s main
flank wear during the rotation phase. Sensitive wear characteristics
are calculated and derived from the Autoregressive Moving Aver-
age (ARMA) model of recorded signals. Also, a metric determined
based on the system’s values is implemented to evaluate the dis-
tance between ARMA tool models with different wear rates and
the baseline model as another wear-sensitive feature. Luo et al.
[10] developed a flank wear rate model combining the cutting
mechanic’s simulation and an empirical model to predict the flank
wear width. Experiments were carried out for the force measure-
ment, and a good agreement was observed between predicted
and measured tool flank wear land width. Ramili et al. [11] devel-
oped a new automatic method for detecting and monitoring wear
on the cutting tool. The experiments were conducted on the CNC
machine and workpiece material taken as the grey cast iron and
thirty cutting tool inserts selected from the same production batch
were used for a statistical study with identical experimental condi-
tions. The three-axis piezo-electric accelerometer was fixed on the
tool holder to carry out measurements in three directions vibra-
tion. All developed vibrational signals apply to mean power analy-
sis theory. Based on the result develop automatic detection tool
wear algorithm for validation of algorithm the second series of
experiments were carried out under different cutting conditions
using fifteen cutting tool inserts. The mean power of the vibratory
signals acquired during the life of each cutting tool was calculated.
The proposed automatic detector was applied to the wear indicator
to validate its performance under various cutting conditions.
Rajeev et al. [12] discussed the cutting tool wear calculated using
ANN. Experiments were conducted on AISI4140 steel using coated
carbide tool in dry hard turning process. Experiments were
designed based on the full factorial design (FFD) and the variation
of cutting force and vibration measured during the experiment
based on the process parameter and measured parameters an
ANN-based tool wear estimator was developed. Finally, the effec-
tiveness of proposed ANN model was presented with an average
error below 10%. In recent work, artificial neural network (ANN)
with the Edgeworth-Pareto approach was used to optimize the cut-
ting parameter in CNC face-milling operations. ANN has predicted
the surface roughness value with accuracy of ± 5.78% for selected
Table 1
Chemical composition EN8 steel material.
C Si Mn S P
0.36–0.44% 0.1–0.4% 0.6–1.0% 0.05% max 0.05% max
Table 2
Mechanical properties of EN8 steel material.
Max stress Yield stress
700–850 N/mm2 465 N/mm2
Materials Today: Proceedings xxx (xxxx) xxx
range of parameters namely spindle speed, feed rate, and cutting
depth [13]. An approach for determining the optimum machining
parameters to minimize surface roughness by integrating Artificial
Neural Network (ANN) and Genetic Algorithm (GA) was presented
[14]. The results obtained by ANN was found with good agreement
with experimental values. To minimum surface roughness in
machining, a predictive and optimization model by coupling artifi-
cial neural network and genetic algorithm was proposed [15].
Experimental investigations were performed to assess the capabil-
ity of proposed approach and it was found with good accuracy of
prediction when compared to experimental values. In another
work, regression analysis (RA) and artificial neural network
(ANN) to predict the surface roughness during hard turning of AISI
52,100 steel. The experiments were planned using Taguchi L27
orthogonal array by considering cutting speed, feed, and depth of
cut. A good agreement was found between the predicted and
experimentally measured surface roughness values [16]. Simulated
Annealing and Neural Networks was used to predict surface rough-
ness produced during machining. The parameters selected were
cutting speed, feed rate, tool rake angle and nose radius. The
response surface model and regression equation was developed
and a good agreement was found between the predicted and
experimental values [17].
2. Experimental details
The experiments have been conducted using high speed con-
ventional lathe in dry condition. The workpiece material selected
is EN8 medium carbon steel. The hardness is 25–26 HRC without
heat treatment. The dimensions of the cylindrical-shaped bar used
for experimentation are 50 mm diameter and 200 mm length. Prior
to the machining tests, the work material is entered and pre-
turned to get rid of the rust layer. The cutting tool used is cemen-
ted carbide inserts. Typical properties of work piece material are
given below Table 1 and Table 2. The cutting tool with ISO designa-
tion CNMG12040 and tool holder PCLNR2020K12 is used for the
experiments.
The line diagram of the experimental setup is shown in Fig. 2.
The conventional tool post of the lathe machine is removed and
the tool dynamometer is fixed in its place. The cables are con-
nected to the dynamometer and the display unit. Display unit is
further connected to the power supply. Then the tool is mounted
in the tool dynamometer slot. For measuring vibration, the
accelerometer’s probe is placed on the top surface of the tool.
The cable of the accelerometer is connected with the vibration
analyser, which is further connected to power supply.
The three major parameter i.e. cutting speed, feed and depth of
cut that significantly affect the turning operation are selected for
the study. All three parameters are considered at three different
levels which is selected based on the trial experiments. Therefore,
nine combinations are tested for a constant time period to know
their effect on the tool wear. Experimental layout with Taguchi
L9 orthogonal array is shown in Table 3.
For tool wear tests, the operation is carried till the tool is worn
out completely i.e up to 0.3 mm flank wear (as per ISO 3685:1993).
Simultaneously force and vibration data are captured. This force
are used to correlate with tool wear and make relationship equa-
tion for online tool wear monitoring, a MATLAB based program is
developed to read the force.
Proof stress Elogation Hardness
450 N/mm2 16% min 25–26 HRC
3
P.J. Bagga, M.A. Makhesana, H.D. Patel et al. Materials Today: Proceedings xxx (xxxx) xxx

Fig. 2. Line diagram of experimental set up.

Table 3
Experimental layout with Taguchi L9 orthogonal array. 2.1. ANN development procedure

Cutting Speed Feed Depth of cut

ANN selected for development of artificial decision making
60 0.5 0.5 model for tool wear monitoring system.
60 1 1
INPUTES FOR ANN: OUTPUT OF ANN
60 1.5 1.5
80 0.5 1 1. Cutting speed 1. Tool wear
80 1 1.5 2. Feed
80 1.5 0.5 3. Depth of cut
100 0.5 1.5 4. The mean value of forces
100 1 0.5
100 1.5 1
5. The RMS value of vibration

Fig. 3. Probability plot for flank wear.

4
P.J. Bagga, M.A. Makhesana, H.D. Patel et al. Materials Today: Proceedings xxx (xxxx) xxx

ANN is a modelling tool widely used when the relationships
between the input and output are highly nonlinear in nature
[11]. In ANN, the relation between the input and output is created
by means of a simulated network consisting of interconnected neu-
rons. The commonly used network is feed –forward neural net-
work topology which consists of three layers. The ANN uses
mapping techniques through which the network output is contin-
ually updated based on the minimum value of mean square error.
In this study, tool wear is predicted based on the neural network.
The best network is found to be a feed forward neural network
with single hidden layer with 4 neurons. Therefore, a network of
structure 3-4-1 is found to be suitable for present work.
3. Results and discussion
Before utilizing the measured values of flank wear, probability
analysis is performed and the same is presented in Fig. 3. It can
be seen from the Fig. 3 that the points are distributed normally

Table 4
Comparison of manual measurement and measurement by ANN model.

Exp. No. Maximum wearPredicted by ANN in microns Maximum flank wear measured manually in microns Difference in microns Percentage difference
1 190 182 8 4.39%
2 290 282 8 2.83%
3 310 321 11 3.42%
4 242 234 12 5.12%
5 428 437 9 2.05%
6 325 333 8 2.40%
7 620 608 12 1.97%
8 225 234 9 3.84%
9 246 260 14 5.38%

Fig. 4. Comparison of tool wear predicted by ANN and measured manually.

Fig. 5. Main effect plot for flank wear.

5
P.J. Bagga, M.A. Makhesana, H.D. Patel et al.
along the centre line and hence same can be considered for further
comparison.
The proposed ANN model is able to predict the maximum flank
wear of the tool. The flank wear is measured manually by micro-
scope to compare it with the measurement obtained by software.
The results of comparison is shown in Table 4 and Fig. 4.
From the table it can be observed that the maximum flank wear
as predicted by ANN are almost similar to the measurement as
done manually. The maximum variation in the result of wear mea-
surement manually and by ANN is 5.38%.
From Fig. 3 it can be concluded that the highest value of flank
wear is observed with experiment no. 7 as it is performed with
highest cutting speed (100 m/min) and higher depth of cut
(1.5 mm). The increasing trend of tool wear is observed with the
increase in cutting speed, and depth of cut as shown in Fig. 5. It
is understood that with higher speed and depth of cut, resulted
in higher cutting temperature and forces leading towards higher
flank wear.
4. Conclusions
The objective of the work is to provide tool wear estimation
method during turning with artificial neural network (ANN). The
performance of ANN model is checked by comparing it with man-
ually measured values of tool wear. It has been observed that cut-
ting speed and depth of cut is the main influencing parameter for
the minimization of tool wear. The results revealed good agree-
ment between the values of tool wear predicted by ANN and man-
ual measurement. The mean percentage difference is 3.48% which
shows that the developed model has good accuracy in predicting
the tool wear. The accuracy achieved with the proposed model
made it as an effective tool for tool condition monitoring in turn-
ing. The work presented here provides machining parameters to
predict tool wear only. Further research can be carried out to anal-
yse the effect of machining parameters on other response variables
such as power consumption, cutting forces, surface roughness, etc.
CRediT authorship contribution statement
P.J. Bagga: Conceptualization, Investigation, Methodology,
Resources. M.A. Makhesana: Investigation, Methodology. H.D.
Patel: Investigation. K.M. Patel: Supervision, Writing - review &
editing.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
Materials Today: Proceedings xxx (xxxx) xxx
Acknowledgements
Authors would like to acknowledge the financial support and
infrastructure facility provided by Nirma University to carry out
the research work.
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