One of the essential elements of automated and intelligent machining processes is accurately predicting tool life. It also helps in achieving the goal of producing quality products with reduced production costs. This work proposes a computer vision-based tool wear monitoring and tool life prediction system using machine learning methods. Gradient-boosted trees and support vector machine (SVM) techniques are used to predict tool life. The experimental investigation on the CNC machine is conducted to study the applicability of the proposed tool wear monitoring system. Experiments are performed using workpiece material made of alloy steel and PVD-coated cutting inserts, and flank wear is monitored. An imaging system consisting of an industrial camera, lens, and LED ring light is mounted on the machine to capture tool wear zone images. Images are then processed by algorithms developed in MATLAB®. Boosted tree methods and the SVM methodology have 96% and 97% prediction accuracy, respectively. Validation tests are carried out to determine the accuracy of proposed models. It is observed that the prediction accuracy of boosted three and SVM is good, with a maximum error of 5.89% and 7.56%, respectively. The outcome of the study established that the developed system can monitor the tool wear with good accuracy and can be adopted in industries to optimize the utilization of tool inserts.
With the increased scope of automated machining processes, one of the essential requirements is the reliable predictions of the tool life. It is crucial to monitor the condition of the cutting tool during the machining process to achieve high-quality machining and cost-effective production. This paper presents a computer vision technique for flank wear measurement and prediction using machine learning, specifically support vector machine (SVM) and boosted decision trees has been used. The proposed methodology for tool wear measurement is illustrated for the CNC machining experimentally. The direct method of tool wear measurement and prediction have been proposed. Flank wear measurement is carried out on PVD coated tool insert, and experiments are performed on an alloy steel workpiece under dry machining. For capturing images, a CMOS camera with a lens mounted on the machine is used. To avoid environmental effects on the images LED ring light is used. Captured tool insert images are provided to the image processing algorithm built-in MATLAB software. The measurement of flank wear is also carried out using a microscope. The prediction accuracy of SVM and optimized boosted tree models is 97% and 96%, respectively, proving prediction algorithms' effectiveness. The findings showcased that the proposed methodology can measure and predict the tool wear with higher accuracy. It has demonstrated the ability to increase cutting tool utilization with the improved surface finish of the machined component.
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