Introduction

INTRODUCTION

Tool Condition Monitoring (TCM) is a critical aspect of modern manufacturing aimed at enhancing tool life, maintaining dimensional accuracy, and preventing unplanned downtime. Among advanced monitoring techniques, vibration signal analysis has emerged as a reliable non-intrusive method for identifying tool wear through changes in dynamic response characteristics. Simultaneously, Finite Element Analysis (FEA) enables detailed simulation of stress distribution and modal behavior under varying cutting conditions. This study integrates vibration-based monitoring with FEA-driven stress and modal analysis to develop a predictive framework for tool wear. By evaluating the influence of cutting speed, tool tip radius, and depth of cut on vibrational frequency, equivalent stress, and deformation, the research establishes a simulation-based approach to anticipate tool degradation in machining operations.