Drill Bit Flank Wear Monitoring System in Composite Drilling Process Using Image Processing

In this research work, an attempt is made to develop the on-line wear state monitoring system during drilling process on Vertical Machining Centre (VMC). The main objectives of the present work is to predict the drill wear states of High Speed Steel (HSS) drill bit during the drilling of a AISI 1040 Steel work piece using standard data acquisition software Lab VIEW by the application of Virtual Instrumentation (VI). The drill bit wear states were analyzed using spindle motor cutting current signals. The effective drill wear model have been developed using spindle motor cutting current signals and the various cutting parameters through Lab VIEW, to predict wear states of the drill-bit. The developed on-line drill wear process monitoring system has been used for the continuous monitoring of the drill-bit status, and to exhibit the drill wear states. It was found that the developed model show a good agreement with the experimental data where the deviation in drill-bit wear is less than 7% for varying cutting conditions.

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MONITORING OF FLANK WEAR AND DAMAGE ON TURNING CUTTING TOOLS BY IMAGE PROCESSING

The Journal of Engineering and Exact Sciences ◽

10.18540/jcecvl6iss2pp0098-0106 ◽

2020 ◽

Vol 6 (2) ◽

pp. 0098-0106

Author(s):

Joseph Kalil Khoury Junior ◽

John Kenneth Schueller ◽

Francisco de Assis Carvalho Pinto ◽

Geice Paula Villibor

Keyword(s):

Image Processing ◽

Flank Wear ◽

Cutting Tools ◽

Artificial Vision ◽

Measurement Tool ◽

Tool Wear Monitoring ◽

Machining Processes ◽

Machine Industry ◽

Wear Monitoring ◽

Processing Techniques

The development of the tool wear monitoring system by machining processes has been well recognized in the machine industry mainly due to the growing demand for product quality and improved productivity. For this, artificial vision systems have been used as a measurement tool in various application areas. Thus, the objective was to develop a system automatic based in the image processing to identify and measure flank wear in machining tool. Image processing techniques, discriminant function, to identify insert breakage, and Hough Transform, to find the flank wear profile, achieved over accuracy. Consequently, 94.3% to identify between worn and broken insert and 0.04 mm mistake in measurement of flank wear width compared with microscope.

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Tool Wear Monitoring: An Automated System Based on Multiple Cutting Force Parameters and Machine Vision Technique

Materials Science Forum ◽

10.4028/www.scientific.net/msf.626-627.5 ◽

2009 ◽

Vol 626-627 ◽

pp. 5-10 ◽

Cited By ~ 2

Author(s):

Yu Teng Liang ◽

Yih Chih Chiou

Keyword(s):

Tool Wear ◽

Machine Vision ◽

Cutting Force ◽

Monitoring System ◽

Flank Wear ◽

Cutting Parameters ◽

Tool Wear Monitoring ◽

Model Based ◽

Wear Monitoring ◽

Vision Technique

This study proposes a tool wear automatic monitoring system based on multiple parameters analysis of cutting force and machine vision technique. A drilling model of cutting parameters (cutting force, coating layer, spindle speed and feed rate) and tool condition (focusing on tool flank wear measurement and analysis) was developed. The experimental design methods developed in this study can be used to optimize cutting parameters efficiently and reliably. The drilling model based on cutting parameters was constructed using Taguchi method. This method enabled evaluation of wear status based on the actual force obtained from a dynamometer. The derived relation is useful for in-process wear monitoring. Tool wear dynamics are extremely complex and not yet fully understood. Therefore, vision-based tool wear monitoring techniques can help elucidate wear progression. In this study, a drilling model based on the machine vision technique was used to establish a direct relation between cutting parameters and tool wear. The object of the experiments was to measure the flank wear of cutting tools with various coatings. The experimental results show that the monitoring system clarifies the relationships between cutting force and multiple cutting parameters.

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