Reduce Tool Wear Research Articles

Reducing Tool Wear with Hybrid Microwave Treated TiCN Coated Tool and Recycled Cooking Oil in MQL Machining of T6061 Aluminium Alloy

Titanium carbo-nitride (TiCN) inserts are vital for cutting operations, particularly in high-temperature conditions. Conventional machining methods lead to rapid wear of tools, frequent need for tool changes, high costs associated with tool replacement, and extensive usage of synthetic cutting fl uids that are environmentally damaging. This study aims to minimise tool wear and promote circular economy. This study examines the process of machining T6061 aluminium alloy using TiCN inserts treated with hybrid microwave (HMW) energy at 220℃ for 20 minutes, with silicon dioxide (SiO2) as the susceptor. Recycled cooking oil is utilised for Minimum Quantity Lubrication (MQL). Analysed were the density, hardness, and microstructural images. Tool wear of TiCN was assessed during dry and wet machining using three different cutting speeds (166, 210, 263 m/min) while maintaining a constant feed rate of 0.6mm/rev and depth-of-cut of 0.4 mm. The findings show the density and hardness of TiCN (HMW) increased by 4% and 7% respectively compared to the TiCN (untreated) insert. The tool wear of TiCN (HMW) has reduced by 5% (MQL) and 24% (dry) compared to the TiCN (untreated) insert. MQL with recycled cooking oil decreased tool wear by 40% compared to dry machining. The microstructural images of the TiCN (HMW) and TiCN (untreated) structures reveal no noticeable variations. TiCN (HMW) has improved wear resistance, and it is particularly beneficial when utilising recycled cooking oil in MQL machining.

A Review of Electroplastic Effect on Difficult‐to‐Machine Materials in Cutting Processing

Electroplastic effect refers to the role of pulsed current, material plasticity, and microstructural properties change, resulting in an increase in the plasticity of the material, the deformation resistance is reduced, and thus improves the processing performance of the phenomenon. This article summarizes the Joule thermal effect and a variety of nonthermal effects of the electrophysical effect mechanism, of which the nonthermal effects include pure electrophysical effect, magnetic field compression effect, and skin effect. The application of electroplastic‐assisted technology in cutting machining, such as turning, milling, drilling, and so on, and the potential application in other manufacturing processes are summarized. The limitations and shortcomings of the electroplastic‐assisted technology are analyzed, including the limitations of the required special equipment, machining platforms, and electric pulse parameters. The effects of different electric pulse parameters on the machinability of various types of difficult‐to‐machine metallic materials are summarized. The electric pulse parameters within a certain threshold range can promote the dynamic recrystallization of the workpiece, enhance the plastic deformation of the cutting zone, reduce the cutting force, improve the surface finish, and reduce tool wear. Finally, this article summarizes and looks forward to the electroplastic‐assisted cutting technology.

Research on hybrid processing of silicon carbide based on laser cutting

Abstract With the rapid development of semiconductor technology, silicon carbide has been widely used in various power electronic device. However, the material has an extremely high hardness ranking second only to diamond, which makes processing difficult. In this work, the two methods of laser cutting and dicing saw are utilized to test the cutting process of silicon carbide respectively, then the appropriate through-cutting process parameters are obtained. The two methods are combined to compare the cutting quality of the three approaches. As a result, the laser cutting is affected by heat with through-cutting 0.5 mm-thick silicon carbide, which results in the rough front-surface edge and much residue, and the cutting groove of the back surface is irregular. The dicing saw having more mechanical stress, resulting in serious tool wear, prone to chipping and micro-cracks and other phenomena, the back surface chipping is as high as 171.6 µm. The hybrid processing method not only reduces the degree of thermal damage, but also reduces tool wear, and the front surface is flat and clean after cutting, without a chipping phenomenon, and the back surface chipping is only 7.9 µm, which is 20 times lower than the dicing saw method.

Study on PCD tool wear in pulsed laser assisted turning Al-50wt % Si alloy

Al-50wt % Si alloy is widely used in aerospace, automotive, electronic packaging and other fields due to its excellent material properties. However, the presence of reinforced particle phase differing in hardness from the alloy matrix phase leads to significant tool wear during turning with PCD tools. Therefore, this paper proposes a pulsed laser assisted turning (PLAT) method combining pulsed laser with conventional turning, which has unique advantages in reducing PCD tool wear. The effects of laser power, pulse width and frequency on tool wear during PLAT were studied by comparative experiments. And the potential mechanism of PLAT to reduce tool wear was revealed by finite element simulation. The results shown that PLAT effectively reduces PCD tool wear compared with conventional turning (CT). The increase of laser pulse width will aggravate tool wear. While, the increase of laser pulse frequency will reduce tool wear. Temperature is the main factor affecting the wear form. The tool mainly experiences abrasive wear at low temperature. However, the predominant type of tool wear shifts to adhesion as the increasing temperature. At the same time, EDS analysis shows that the rise in temperature results in an elevation of the O element content within the wear region, which proves that temperature is also the decisive factor affecting oxidative wear. This study provides valuable insights into actual machining involving Al-50wt % Si alloys and gives strategies for reducing PCD tool wear using PLAT.

Ultrasonic-assisted ultra-precision turning of zinc-selenide with straight-nosed diamond tools

This study proposes a novel ultra-precision machining technology that uses ultrasonic vibration and a straight-nosed diamond tool to improve the processing of the brittle optical material zinc selenide (ZnSe). This research addresses the challenges posed by Poisson's effect in ultrasonic vibration-assisted single-point diamond turning, which causes bending vibration along the depth of cut, resulting in lower machining efficiency and surface quality. This study analyses the relationship between one-dimensional ultrasonic vibrations at the diamond tool edge and induced bending vibrations using both theoretical and experimental methods. By investigating ultrasonic vibration dynamics in the feed direction and at the straight cutting edge, the results showed that ultrasonic vibration helps to improve the ductile-brittle transition ratio of the cutting area and surface quality. These improvements are accomplished by regulating the cutting position at the tool cutting edge, adjusting cutting parameters, and optimizing ultrasonic parameters. The machined surface roughness of ZnSe is reduced by approximately 30-46% at higher feed rates under ultrasonic vibration with straight-nosed diamond tools. The findings demonstrate the potential of this novel technology to reduce tool wear and brittle fractures, resolving the challenge of ultra-precision machining for optical materials.

Analysis of the Deterioration Mechanisms of Tools in the Process of Forging Elements for the Automotive Industry from Nickel-Chromium Steel in Order to Select a Wear-Limiting Coating.

This paper provides a detailed analysis of the operation of representative forging tools (in the context of using various surface engineering techniques) used in the process of the hot forging of nickel-chromium steel elements. The influence of the microstructure and hardness of the material on the durability of the tools is also discussed, which is important for understanding the mechanisms of their wear. The research showed that the standard tools used in the process (only after nitriding) as a reference point worked for the shortest period, making an average of about 1400 forgings. In turn, the tools coated with the CrAlSiN coating allowed for the production of the largest number of forgings, reaching 2400 pieces, with uniform wear. In comparison, the tools with the CrAlBN coating made 1900 forgings. Three-dimensional scanning analysis showed that CrAlSiN- and CrAlBN-coated tools have lower volumetric wear, around 41-43 mm3, compared to 59 mm3 for nitrided tools. For a better comparison of tool life, the authors proposed the Z-factor, as the material loss to the number of forgings. The CrAlSiN coating showed the lowest material loss, despite a slightly higher Z-factor value compared to the CrAlBN coating. The use of hybrid coatings such as CrAlSiN and CrAlBN significantly reduces tool wear while increasing service life compared to tools that are nitrided only.

Quantitative Analysis of Basalt Damage Under Microwave Radiation Utilizing Uniaxial Compression and Nuclear Magnetic Resonance (NMR) Experiments

Microwave-assisted rock breaking is recognized as an effective technology for reducing tool wear and enhancing rock-breaking efficiency. In this study, basalt rock was irradiated with a microwave power of 3 kW and 6 kW for 30 s, 60 s, 90 s, and 120 s. Subsequently, uniaxial compression, uniaxial loading and unloading, and acoustic emission tests were performed. The damage evolution of basalt was assessed through non-destructive acoustic testing methods and nuclear magnetic resonance (NMR) techniques. The results showed that the P-wave velocity, uniaxial compressive strength (UCS), and modulus of elasticity (E) exhibited varying degrees of deterioration as the microwave radiation time increased. An increase in microwave radiation time and power led to heightened acoustic emission activity in basalt and a significant rise in the proportion of shear cracks during uniaxial compression. From an energy perspective, microwave irradiation decreased the energy storage capacity of the basalt specimen prior to its peak point, with increased power and duration. At a microscopic level, porosity and the macroporous fractal dimension increased with extended microwave radiation time and power, indicating that microwave irradiation facilitated the growth of larger fractal pore structures. The findings of this study offer scientific insights for the application of microwave-assisted rock crushing.

Enhancement of Machining Performance of Ti-6Al-4V Alloy Though Nanoparticle-Based Minimum Quantity Lubrication: Insights into Surface Roughness, Material Removal Rate, Temperature, and Tool Wear

In competitive industry, economical and environmentally friendly production techniques are essential. In this sense, cleaner and more sustainable machining techniques are the industry’s focus. In addition to green methods, effective parametric control is necessary for hard-to-cut materials, particularly titanium Ti-6Al-4V, which is extensively used in a diversity of industries, including aerospace, medical, and military applications. Therefore, the current study aims to improve the machining performance of Ti-6Al-4V alloy using sustainable lubrication conditions. The effect of Al2O3 nanoparticles based on the minimum quantity lubrication (N-MQL) condition on surface quality and productivity are compared with minimum quantity lubrication (MQL). The performance measures, including surface roughness (Ra), material removal rate (MRR), and temperature, are evaluated at three machining variables, i.e., cutting speed (Vc), feed rate (f), and depth of cut (ap). These performance measures are further assessed by tool wear and surface morphology analysis. ap, f, and Vc are the most influencing parameters for Ra, MRR, and temperature, regardless of lubrication mode. The optimized values of RA of 0.728443 µm, MRR of 2443.77 m3/min, and temperature of 337 °C are achieved at N-MQL. For the N-MQL state, the optimized values of Ra of 0.55 µm, MRR of 2579.5 m3/min, and temperature of 323.554 °C are attained through a multi-response optimization desirability approach. Surface morphology analysis reveals a smooth machined surface with no obvious surface flaws, such as feed marks and adhesion, under N-MQL conditions, which significantly enhances the surface finish of the parts. The machining performance under the N-MQL condition has been enhanced considerably in terms of an improvements in surface finish of 32.96% and MRR of 11.56%, along with a decrease in temperature (17.22%) and higher tool life (326 s) than MQL. Furthermore, Al2O3 is advised over MQL because it uses less energy and has reduced tool wear and improved surface quality, and it is a cost-effective and sustainable fluid.

Enhancing tool life through innovative process control in wood-based machining

ABSTRACT This study demonstrated a process control strategy for extending tool life in wood-based machining. A feedback control technique regulated tool spindle speed while cutting to maximize tool performance. Machining of melamine-coated particleboard was conducted on a computer numerical control router with tungsten carbide inserts. Four cutting scenarios were applied: constant low spindle speed, constant high spindle speed, step function cutting and cutting using feedback control technique. After each test, panel chipping and tool wear were assessed to determine the effect of varying the spindle speed on tool wear and panel chipping. The findings indicated that although tool wear increased, panel chipping decreased when the spindle speed remained continuously high. A constant low spindle speed increased panel chipping and decreased tool wear. Raising the spindle speed in the step function setting reduced tool wear and panel chipping, but it was not apparent when these speed adjustments should be made. The feedback control technique greatly extended the tool life, improving surface quality. The study contributes significantly to wood-based machining procedures and greatly impacts the woodworking sector. The advantages of improved tool life and increased productivity justify the need for more research in this area.

Optimization of microwave drilling parameters for pine needles and rice husk PLA composites

ABSTRACT In this study, drilling analysis was conducted on pine needles and rice husk reinforced PLA composites to optimize the process parameters to improve hole quality and reduce tool wear. Results showed that drilling at 180 W microwave power with the feed rate of 150 mm/min yielded the maximum circularity of 0.94 and a tool wear of 0.17 × 10−2 g. The maximum material removal rate of 2.39 × 10−2 g/s was achieved at 540 W microwave power and a feed rate of 120 mm/min. Regression analysis was utilized to define relationships between process parameters and responses for pine needle and rice husk powder-reinforced PLA composites. ANOVA validated the model’s significance, demonstrating a correlation above 95% between experimental results and predicted values. The optimal process parameters for achieving high-quality holes in pine needles and rice husk reinforced PLA composites were found to be at 180 W of microwave power and 144 mm/min of feed rate.

Preliminary study on the cutting force and shape error in turning of X5CrNi18-10 shafts with small feed

Measuring cutting forces and shape errors is crucial for understanding and optimizing machining processes. These factors significantly describe the quality, accuracy, and efficiency of manufacturing operations. In this study, the focus is on the turning of X5CrNi18-10, a widely used austenitic stainless steel known for its excellent corrosion resistance and mechanical properties, but challenging machinability due to work-hardening tendencies and high toughness. The study investigates the effects of three key machining parameters—feed rate, depth of cut, and cutting speed—on cutting forces and shape errors, particularly cylindricity. Cutting forces directly impact tool wear, energy consumption, and surface finish, while shape errors reflect the geometric deviations from the intended design, affecting the functionality of machined components. By analyzing these parameters, the study aims to provide insights into the interactions between cutting dynamics and material behavior during turning. It evaluates how variations in feed, depth of cut, and cutting speed influence the magnitude of cutting forces and the resulting geometric precision. These findings contribute to the development of optimized machining strategies, ensuring improved dimensional accuracy, reduced tool wear, and enhanced overall process stability for X5CrNi18-10 and similar materials.

Towards sustainable machining: an experimental study of eco-friendly MQL and its impact on machinability and future opportunities

Abstract Enforcement of stricter environmental policies calls for alternative methods that could reduce the usage of cutting fluid during machining. Thus, dry machining and minimum quantity lubrication (MQL) machining are gaining practical importance. From this perspective, the development of new biodegradable MQL fluids and their performance assessment during machining is acquiring global attention. In this work, Jatropha crude oil (JCO) is chemically transformed into an epoxidized product and used as a MQL fluid. The turning experiments are conducted on Nimonic 80A under varying cutting speeds, and feed rates with constant depth of cut to examine the effects on machinability characteristics. The experiments are conducted under three different environments viz. dry, conventional minimum quantity lubrication (CMQL) and epoxidized minimum quantity lubrication (EMQL). The cutting force, tool flank wear, surface roughness and chip morphology are used as performance indicators. Regarding environmental concerns, the EMQL proved to be a viable substitute for CMQL as it demonstrated the lowest cutting force, tool wear and surface roughness. EMQL can reduce tool wear and surface roughness to the extent of about 54% and 22% as compared to the dry machining environment. The cutting force is reduced by about 13% and 34% by adopting CMQL and EMQL respectively even under the high feed (f = 0.45 mm min−1) condition. The sustainability assessment model developed using the Pugh matrix environmental approach disclosed EMQL system helps in attaining the desired machinability qualities while offering environmental friendliness and cleaner production.

Experimental and numerical analysis of high-pressure gas-driven rock particle impact and fragmentation rock technology

Aiming at the problems of fast tool wear and low tunneling efficiency in hard rock tunneling process, a granite particle impact rock breaking technology is proposed to impact the rock mass of the tunneling face in advance to reduce tool wear. By simulating the process of granite particle impact rock breaking, the feasibility of granite particle impact rock breaking is verified. The impact velocity and new surface area of granite were obtained by high-speed camera and three-dimensional scanner test. The influence factors of gas pressure and granite particle quality were analyzed. It is concluded that increasing gas pressure can effectively increase the new surface area of rock failure and improve the failure effect. Improving the quality of granite particles does not continuously increase the impact kinetic energy. When the product of granite particle quality and impact kinetic energy reaches a critical value, continuing to increase the quality will not improve the impact damage effect of granite. The impact kinetic energy of granite particles impacting granite shows a linear relationship with the new surface area.

Micro milling mechanism and tool wear of Unidirectional HfZrTiTaNbCu0.2 fiber reinforced aluminum matrix composites

This study delves into the micro milling and tool wear mechanisms of 2A97 aluminum matrix composites reinforced with HfZrTiTaNbCu0.2 fibers. Finite element analysis models the fibers as uniformly distributed cylindrical entities within the matrix, applying various material constitutive laws, failure, and evolution criteria to simulate milling at three specific angles (45°, 90°, 135°). The research examines the effects of milling parameters, fiber orientations, and tool coating thickness on cutting forces, temperatures, surface roughness, and tool wear. Key findings include: These forces escalate with both cutting speed and depth of cut. Notably, at a feed rate of 68 μm/z, the cutting force is 1.5 times higher compared to 58 μm/z.An increase in milling parameters leads to higher cutting temperatures. Differences of 12 °C and 10 °C were noted at varying depths of cut (10–25 μm) and cutting speeds (1000–1200 mm/s), respectively. As the fiber angle increases, cutting forces first decrease and then rise, with fibers oriented at 90° experiencing only 53 % of the force compared to those at 135°. Similarly, cutting temperatures follow this trend, with a 26 °C difference between 45° and 90° fibers. This factor is positively correlated with depth of cut and fiber angle. Surface roughness at a 55 μm depth is 4.3 times that at 10 μm, and 135° fibers show 2.7 times the roughness of 45° fibers. However, within feed rates of 48–58 μm/z and cutting speeds of 800–1200 mm/s, there is a notable decrease in surface roughness. Variations in cutting parameters, fiber orientations, and tool coating thickness significantly influence peak tool stress. Stress concentration at the central groove tends to reduce tool wear, whereas stress concentration at the peripheral edge or strain concentration at the bottom edge exacerbates it.

An Automated Feature-Based Image Registration Strategy for Tool Condition Monitoring in CNC Machine Applications.

The implementation of Machine Vision (MV) systems for Tool Condition Monitoring (TCM) plays a critical role in reducing the total cost of operation in manufacturing while expediting tool wear testing in research settings. However, conventional MV-TCM edge detection strategies process each image independently to infer edge positions, rendering them susceptible to inaccuracies when tool edges are compromised by material adhesion or chipping, resulting in imprecise wear measurements. In this study, an MV system is developed alongside an automated, feature-based image registration strategy to spatially align tool wear images, enabling a more consistent and accurate detection of tool edge position. The MV system was shown to be robust to the machining environment, versatile across both turning and milling machining centers and capable of reducing tool wear image capturing time up to 85% in reference to standard approaches. A comparison of feature detector-descriptor algorithms found SIFT, KAZE, and ORB to be the most suitable for MV-TCM registration, with KAZE presenting the highest accuracy and ORB being the most computationally efficient. The automated registration algorithm was shown to be efficient, performing registrations in 1.3 s on average and effective across a wide range of tool geometries and coating variations. The proposed tool reference line detection strategy, based on spatially aligned tool wear images, outperformed standard methods, resulting in average tool wear measurement errors of 2.5% and 4.5% in the turning and milling tests, respectively. Such a system allows machine tool operators to more efficiently capture cutting tool images while ensuring more reliable tool wear measurements.

Modeling & optimization of Ti6Al4V turning for sustainable shearing considering rake angle

Titanium alloys, such as Ti6Al4V, have become increasingly prevalent in aerospace and biomedical industries owing to their exceptional mechanical properties and corrosion resistance. However, the machining of these alloys presents significant challenges including high tool wear, poor surface finish, and low productivity. This study focused on enhancing the machinability of Ti6Al4V during CNC turning using the Taguchi optimization method. This approach aims to identify the optimal cutting parameters that minimize the surface roughness, flank wear, and crater wear, thereby improving the overall machining performance. This study systematically investigated the influence of various cutting parameters on machining outcomes. The experimental results demonstrate that the Taguchi method effectively determines the optimal process parameters, leading to a significant reduction in surface roughness and tool wear. These findings highlight the potential of the Taguchi optimization technique for achieving improved machinability and sustainability in the machining of Ti6Al4V.

Evaluation of Sustainability and Cost Effectiveness of Using LCO2 as Cutting Fluid in Industrial Hard-Turning Installations

Conventional oil-based emulsions used in hard-turning processes present significant environmental and economic challenges, including high waste generation and hazardous disposal requirements. In response, cryogenic CO2 cooling has gained attention as a sustainable alternative, offering improved productivity, reduced tool wear and a diminished environmental footprint. While technical advances have been reported, the industrial adoption of cryogenic cooling is still limited due to the lack of clear data on its actual viability. This paper moves beyond the analysis of the technical performance of cryogenic CO2 cooling analyzed in previous works to conduct a detailed evaluation of its environmental and economic performance when machining roller bearing components with pCBN tools on a hard-turning installation. Utilizing Life Cycle Assessment (LCA) and Return-on-Investment (ROI) methodologies, this study compares cryogenic CO2 with traditional cooling methods, quantitatively assessing the environmental impact and economic viability across different manufacturing scenarios. The findings reveal that cryogenic cooling can outperform conventional cooling regarding both environmental impact and cost-effectiveness thanks to the tool life improvements provided by cryogenic cooling, specifically in cases where high tool consumption is generated during hard-turning operations. These results provide critical insights for selecting cooling strategies during the design phase of industrial turnkey projects, highlighting the potential of cryogenic CO2 as a superior solution for sustainable and efficient hard-turning operations.

Influence of the Cooling Temperature on the Surface Quality in Integrated Additive and Subtractive Manufacturing of Aluminum Alloy.

The surface quality of parts processed by laser additive manufacturing, especially laser-based directed energy deposition (LDED), makes it difficult to meet actual use requirements. In addition, defects generated during the long-term additive manufacturing process need to be removed in time. Therefore, laser additive and subtractive manufacturing is of great significance for additive manufacturing. The main difference between laser additive-subtractive manufacturing and pure subtraction is that a cooling temperature is required due to the laser process. Therefore, this work studies the temperature variation regularity during LDED and the milling processes, as well as the surface roughness, cross-sectional microstructure, and tool wear under different cooling temperatures for milling. The results show that there is a "turning point temperature" in LDED, and the value of the turning point temperature gradually increases with heat accumulation, which affects the initial temperature of the subtractive manufacturing. When subtracting, a high initial temperature improves surface quality and reduces tool wear, but an excessively high temperature will cause the aluminum alloy to adhere to the tool. Then, the smear metal is difficult to effectively remove, deteriorates the milling quality, and aggravates tool wear. It is found that the higher the cooling temperature generated, the wider the thermally insulated shear band. The insulated shear band may affect the quality of the additive and subtractive manufacturing. Finally, it is determined that the milling temperature of aluminum alloy in this work condition is about 100 °C.

Comparative study on machinability and surface integrity of γ-TiAl alloy in laser assisted milling

γ-TiAl alloy, as a typical difficult-to-cut material, is considered to have great potential in aero-engine manufacturing. However, it is difficult to achieve high-quality processing of γ-TiAl alloy using traditional cutting processes, due to the room temperature brittleness and high strength of theγ-TiAl alloy. This study proposes a fiber laser assisted machining (LAM) method to improve the cutting quality of γ-TiAl alloy, which attempts to address current challenges in applications of aero-engine manufacturing. The machinability and surface integrity of γ-TiAl specimens using LAM method and conventional milling are analyzed and discussed. Through cutting force testing, chip morphology research, surface hardness testing, and microstructure observation, it is found that the LAM method significantly improves the machinability and machined surface integrity of γ-TiAl specimens. Furthermore, the cooling strategies in LAM is discussed through comparative cutting experiments. During continuous LAM processing, it is found that the rapid heat accumulation effect induces tool adhesive wear, which leads to the decline of cutting quality and tool failure. The experimental results indicate that liquid cooling is an available strategy to reduce tool wear. However, it should be noted that periodic thermal shock by liquid cooling causes surface roughness to increase in continuous LAM processing. Through this work, it is proved that the LAM method can improve machinability and surface integrity of γ-TiAl specimens, which has great potential and worths further studies.

Enhancing Machining Efficiency: Real-Time Monitoring of Tool Wear with Acoustic Emission and STFT Techniques

Tool wear in machining is inevitable, and determining the precise moment to change the tool is challenging, as the tool transitions from the steady wear phase to the rapid wear phase, where wear accelerates significantly. If the tool is not replaced correctly, it can result in poor machining performance. On the other hand, changing the tool too early can lead to unnecessary downtime and increased tooling costs. This makes it critical to closely monitor tool wear and utilize predictive maintenance strategies, such as tool condition monitoring systems, to optimize tool life and maintain machining efficiency. Acoustic emission (AE) is a widely used technique for indirect monitoring. This study investigated the use of Short-Time Fourier Transform (STFT) for real-time monitoring of tool wear in machining AISI 4340 steel using carbide tools. The research aimed to identify specific wear mechanisms, such as abrasive and adhesive ones, through AE signals, providing deeper insights into the temporal evolution of these phenomena. Machining tests were conducted at various cutting speeds, feed rates, and depths of cut, utilizing uncoated and AlCrN-coated carbide tools. AE signals were acquired and analyzed using STFT to isolate wear-related signals from those associated with material deformation. The results showed that STFT effectively identified key frequencies related to wear, such as abrasive between 200 and 1000 kHz and crack propagation between 350 and 550 kHz, enabling a precise characterization of wear mechanisms. Comparative analysis of uncoated and coated tools revealed that AlCrN coatings reduced tool wear extending tool life, demonstrating superior performance in severe cutting conditions. The findings highlight the potential of STFT as a robust tool for monitoring tool wear in machining operations, offering valuable information to optimize tool maintenance and enhance machining efficiency.