In-situ pulse monitoring system through current peak detection is developed to study the influence of tool wear compensation factor in-line.

The method of off-line adaptive control of tool wear compensation factor is proposed and experimentally validated.

In-line tool wear prediction and subsequent compensation is realized through in-situ pulse counting.

The combined off-line and in-line adaptive control method is implemented on machine-level to machine precision 3D micro cavities in a more efficient way, without the necessity to predefine Z-axis tool feed in the NC trajectory before machining.