Tool Wear Monitoring using Image Processing Techniques

Abstract

Monitoring tool wear is very important in machining industry as it may result in loss of dimensional accuracy and quality of finished product. Generally there are two techniques follow in the industry to decide the finish of tool life and replace it. In one case, where the cost of a workpiece is higher than the tool is replaced prematurely before its useful life has finished. This saves the costly workpiece from getting damaged. In other cases, where the cost of the part is not worthy, the tool is used till the finish of the useful life. Once the tool reaches the finsh of tool life and part quality affected, the tool is changed and the workpiece is either replaced or rework is carried out. Generally, the industry utilizes past data to determine the useful life of the tool. There are two ways to know the tool wear: Direct and Indirect. Generally, tool wear is measured directly using an optical microscope which is an offline and time-consuming technique. In the indirect technique, the parameter that is affected by tool wear is measured. Many researchers have selected the parameter like the current, force, surface finish, temperature etc. and correlated it with tool wear and tool life. After carryout literature review, it has been observed that image processing methods has a lot of scope measurement of tool wear. Digital image processing methods automate the task of measurement and monitoring of tool wear. This work is focused on implementing digital image processing methods to automate the task of two dimensional flank wear measurement.