Optimal tool replacement with nondecreasing tool wear

This paper addresses the problem of optimal tool replacement, specifically the selection of the optimal initial tool setting and the tool replacement cycle. A tool replacement model is derived by assuming tool wear is the most important factor affecting machining accuracy. The economic loss due to the deviation of a part from its target value is characterized by a quadratic function. The model is based on an empirical approach and does not attempt to explain the underlying physics of tool wear.