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Applied Sciences
Volume 16
Issue 2
10.3390/app16020958
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

Study on Methods and a System for Real-Time Monitoring of the Remaining Useful Life of a Milling Cutter

by
Shih-Ming Wang
*,
Wan-Shing Tsou
,
Jian-Wei Huang
,
Shao-En Chen
and
Chia-Che Wu
Department of Mechanical Engineering, National Chung Hsing University, Taichung 40227, Taiwan
*
Author to whom correspondence should be addressed.
Appl. Sci. 2026, 16(2), 958; https://doi.org/10.3390/app16020958 (registering DOI)
Submission received: 25 October 2025 / Revised: 13 January 2026 / Accepted: 14 January 2026 / Published: 16 January 2026
(This article belongs to the Special Issue From Human–Machine Interaction to Human–Machine Cooperation: Status and Progress, 2nd Edition)
Versions Notes

Abstract

Tool wear degrades sharpness and durability, causing poor surface quality, dimensional errors, and high costs. Precise RUL prediction optimizes production, reduces rework, and prevents downtime. Conventional replacement relies on experience and risks inaccuracy. Real-time monitoring enables optimal intervals. Predictive maintenance cuts tooling costs and ensures quality. Industry 4.0 integrates sensors for intelligent wear management. This study applies GRNN to predict RUL with minimal TMD. A C#-based system with intuitive HMI was validated in real machining.
Keywords: tool wear monitoring; GRNN; RUL; spindle current; data augmentation tool wear monitoring; GRNN; RUL; spindle current; data augmentation

Share and Cite

MDPI and ACS Style

Wang, S.-M.; Tsou, W.-S.; Huang, J.-W.; Chen, S.-E.; Wu, C.-C. Study on Methods and a System for Real-Time Monitoring of the Remaining Useful Life of a Milling Cutter. Appl. Sci. 2026, 16, 958. https://doi.org/10.3390/app16020958

AMA Style

Wang S-M, Tsou W-S, Huang J-W, Chen S-E, Wu C-C. Study on Methods and a System for Real-Time Monitoring of the Remaining Useful Life of a Milling Cutter. Applied Sciences. 2026; 16(2):958. https://doi.org/10.3390/app16020958

Chicago/Turabian Style

Wang, Shih-Ming, Wan-Shing Tsou, Jian-Wei Huang, Shao-En Chen, and Chia-Che Wu. 2026. "Study on Methods and a System for Real-Time Monitoring of the Remaining Useful Life of a Milling Cutter" Applied Sciences 16, no. 2: 958. https://doi.org/10.3390/app16020958

APA Style

Wang, S.-M., Tsou, W.-S., Huang, J.-W., Chen, S.-E., & Wu, C.-C. (2026). Study on Methods and a System for Real-Time Monitoring of the Remaining Useful Life of a Milling Cutter. Applied Sciences, 16(2), 958. https://doi.org/10.3390/app16020958

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