System and method for real-time monitoring and predicting wear of a cutting tool

A system for monitoring and predicting wear of a cutting tool used for machining a workpiece, comprising:

• a cutting tool having a shank and a cutting head, the cutting head having an insert receiving pocket for receiving a cutting insert;
• and
• a split, modular and wireless wear detection system comprising:
• one or more sensors mounted to the cutting tool for generating a data signal;
• a data recording and data transmitting device for receiving and recording the data signal generated by the one or more sensors and for generating and transmitting a data signal to a processor,
• wherein the processor applies a machine learning data processing technique in real time to monitor and/or predict a condition of various components and/or parameters of the system during a metal cutting operation;
• wherein the machine learning data processing technique comprises a seven-step machine learning process;
• and
• wherein the seven-step machining learning processing technique comprises:
• 1) gathering data;
• 2) data preparation;
• 3) choosing a model;
• 4) training;
• 5) evaluation;
• 6) hyperparameter tuning;
• and 7) prediction.