Study on the Correlation Between Surface Roughness and Tool Wear Using Automated In-Process Roughness Measurement in Milling

Abstract

The growing demand for automated production systems is driving continuous innovation in smart and data-driven manufacturing technologies. In the field of production metrology, the trend is shifting from using measurement laboratories to integrating measurement systems directly into production processes. This has led the Institute of Manufacturing Technology at TU Vienna together with its partners to develop a roughness measurement device that can be directly integrated into machine tools. Building on this foundation, this study tries to find applications beyond mere surface roughness assessment and demonstrates how the device could be applied in broader contexts of manufacturing process monitoring. By linking surface measurements with tool wear monitoring, the study establishes a correlation between surface roughness and wear progression of indexable inserts in milling. It demonstrates how in situ data can support predictive maintenance and the real-time adjustment of cutting parameters. This represents a first step toward integrating in situ metrology into closed-loop control in machining. The experimental setup followed ISO 8688-1 guidelines for tool life testing. Indexable inserts were operated throughout their entire service life while surface roughness was continuously recorded. In parallel, cutting edge conditions were documented at defined intervals using focus variation microscopy. The results show a consistent three-phase pattern: initially stable roughness, followed by a steady increase due to flank wear, and an abrupt decrease in roughness linked to edge chipping. These findings confirm the potential of integrated roughness measurement for condition-based monitoring and the development of adaptive machining strategies.