Tool wear is a decisive factor affecting product quality. The intense friction at the tool-chip and tool-workpiece interfaces, coupled with high-temperature cutting environments, are the primary causes of tool wear. Due to limitations in measurement locations and methods, direct observation of mechanical and thermal evolution at the interface is nearly impossible. The iKIT wireless extrasensory toolholder demonstrates its testing advantages，achieving real-time, high-frequency monitoring of the deformation behavior during machining (cutting, drilling, etc.), Simultaneously, the synchronously presented data effectively assists users in analyzing tool usage.

A

The stability of the monitored signal values indicates changes in the tool surface condition associated with tool degradation. For the normal tool, the data for all four signal groups remains stable. However, as tool wear progresses over machining time, the values for all four signal groups gradually increase. At the same time, abnormal spikes can be observed in all of them, i.e. waveform distortion. which is due to the chips or broken cutting teeth do not participate in the cutting process.

B

Polar plot provides a more intuitive representation of tool usage. For the normal tool, the cutting edge angles in the polar plot are symmetrically distributed. As the tool wears, the distribution becomes asymmetrical and the cutting edge profile becomes less distinct. In other words, by distinguishing the differences in polar plot presentation between normal/healthy tools and worn tools, it is possible to determine whether the tool has failed due to wear.