The experimental parameters and materials used are as follows:

Schematic diagram of the machining process (left) and a photo of the sample after drilling (right):

When drilling reached the 9th hole, the software data showed anomalies: the values of the two-way bending moments suddenly increased, and the polar plots exhibited extreme fluctuations. Analysis of the data revealed that at the time of the anomaly, the axial force (F) did not change significantly, while the torque (M) suddenly increased from 8.34 Nm to 20.36 Nm. while the amplitude of the bending moments in both directions nearly tripled, increasing from 40.59 Nm (B1) and 33.92 Nm (B2) to 97.50 Nm (B1) and 106.48 Nm (B2), respectively.

Based on the data analysis and the corresponding machining conditions, it can be determined that the tool has fractured. At this point, the machining program should be stopped, and the tool’s condition should be observed and photographed using a tool profilometer, as shown in the figure. As the figure indicates, the tool has a fractured cutting edge. Therefore, it is evident that real-time data acquisition and display effectively aid in assessing tool wear and fracture. Changes in torque and bidirectional bending moments can serve as key indicators for such assessments.