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The mechanical removal of chips from the workpiece is called material removal. If the number of cutting edges and their macro-geometry and orientation are known, the operation is called a cutting process. These cutting processes play a major role in manufacturing because of their wide field of applications. Many different materials with a wide variety of shapes can be machined by cutting. Both roughing for high productivity and finishing to meet high precision demands can be achieved by cutting. . | Sensors in Manufacturing. Edited by . Tbnshoff I. Inasaki . Copyright 2001 Wiley-VCH Verlag GmbH I 203 ISBNs 3-527-29558-5 Hardcover 3-527-60002-7 Electronic I Cutting Processes I. Inasaki B. Karpuschewski Keio University Yokohama Japan . Tönshoff Universität Hannover Hannover Germany Introduction The mechanical removal of chips from the workpiece is called material removal. If the number of cutting edges and their macro-geometry and orientation are known the operation is called a cutting process. These cutting processes play a major role in manufacturing because of their wide field of applications. Many different materials with a wide variety of shapes can be machined by cutting. Both roughing for high productivity and finishing to meet high precision demands can be achieved by cutting. A further distinction is made according to the number of cutting edges. Single-point cutting processes are turning as the most important method planing and shaping. If more than one cutting edge integrated in a tool is contributing to the material removal the process is called multi-point cutting. Milling drilling and broaching are the most important operations in this field. Any cutting process is possible only by applying forces to remove the chips from the workpiece. These forces may also cause deformations of the tool the machine tool or the workpiece thus leading to dimensional errors on the part. The cutting energy as a result of force application under specific speeds is to a large extent converted to heat which may cause thermal problems for the participating components. Mechanical and thermal loads are also responsible for a temporal change of the tool condition leading to a change in the process output. Hence sensors are needed to monitor all the mentioned undesirable but inevitable changes of the process state to avoid any damage of equipment or machined parts. Problems in Cutting and Needs for Monitoring Major tasks which should be attained with a