In machining as a result of the cutting motion, the surface of workpiece will be influenced by cutting parameters, cutting force and vibrations etc. But the effects of vibrations have been paid less attention. Thus, by monitoring the machined surface topography of the workpiece and extracting the relevant information the cutting process and tool wear state should be able to be monitored and quantified. In a automated manufacturing systems, an accurate detection of the tool conditions under

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... cutting conditions so that worn tools can be identified and replaced in time. This work is aimed at to predict the effects of displacements due to vibration during face milling and to examine the surface topography of different workpiece materials so as to develop a base for on-line tool condition monitoring system. First part consists of a data acquisition and signal processing using acousto optic emission sensor (i.e., laser doppler vibrometer) for on line tool condition monitoring and the second part of the work presents the vision based surface topography analysis of machined surfaces during the progression of the tool wear. The encouraging results of the work paves the way for the development of a real-time, low-cost, and reliable tool-condition-monitoring system.