Many machining parameters are directly influenced by tool wear and tool geometry evolution. In conventional tool condition assessment, the wear criterion \({V}_{b}\) is commonly employed. However, this criterion merely reflects the flank wear width on the main flank face. This study aims to propose a novel methodology based on the integration of microscopic imaging and CAD technology. This approach enables the evaluation of the total flank wear area over the entire flank face, including the tool nose region. Notably, the tool nose accounts for approximately 30% of the total wear area. The output of this measurement provides a comprehensive indicator of how various machining parameters, such as tool orientation angle and depth of cut, influence the process. In the present work, the combined influence of this parameter on surface topography and surface morphology is investigated qualitatively. The study also explains its relationship with tool wear and the defects imprinted on the cutting tools. In addition, the role of machining environments under critical cutting conditions is examined. The results show that cryogenic machining, under the most severe conditions performed in this research (vc = 150 m/min and ap = 2.5 mm), reduced the flank face wear area by 69.26%, 21.64% and 37.78% compared to dry, wet, and minimum quantity lubrication environments, respectively. This improvement is attributed to the preservation of tool hardness and coating stability. Although cryogenic cooling effectively limited thermal softening, the MQL condition showed superior protection of the rake surface due to reduced friction and the presence of a lubricating oil film.
