Abstract:The cutting condition independent method based on force model coefficients is applied to monitor tool wear status. However, its application in an actual industrial environment is restricted due to multiple reasons, such as the interference in normal processing, lagging in real-time tracking, difficulties in sensor installation and high cost. In light of these problems, spindle cutting current coefficients are introduced. First, the cutting current model of a sharp tool is built with cutting force coefficients and spindle current. Then, the coefficients are identified, and the cutting current of a sharp real tool with the same parameters as the simulated model is estimated in real-time. The difference between the actual cutting current from that of the estimated value is tracked and the wear status is judged; Finally, the correctness and validity of the method are verified by experiments and comparison with force signals. The experimental results show that this method can replace the method based on cutting force coefficients. The proposed method recognizes the wear status without interference and narrowly lags behind in real-time tracking.