On-line knowledge of tool engagement and flank wear is critical for su
ccessful adaptive control of a machining operation. A method combining
a mechanistic model and empirical relationships has been developed fo
r helical end milling operations. Computation of cutting tool engageme
nts and flank wear width occurs in real time as the cutting progresses
using averaged force data. Response surface methodology has been used
to investigate the effects of the process and operating variables on
the process-dependent parameters; a second order relationship was obta
ined. The approach can also determine variation of wear land width alo
ng the length of the tool as axial engagement changes.