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A novel image-based method for wear measurement of circumferential cutting edges of end mills

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Abstract

In the manufacture of metal parts, it is crucial to measure the tool wear accurately and quickly to improve machining automation, avoid tool change error, and perform tool wear compensation. In this study, an image-based on-machine and direct measurement model is proposed for the circumferential cutting edge wear of a milling cutter. First, a charge-coupled device sensor is applied to collect the one-dimensional (1D) projected images of the cross section on a circumferential cutting edge. The multiple-frame 1D images under one rotation angle of cutter are stitched into a rectangular image. Then, the multiple rectangular images in one rotation of the cutter are stitched to form a two-dimensional (2D) image. Also, the image edges are positioned through the image edge detection algorithms. Finally, based on the outer edges of the rectangular images for a same cutting edge, the tool diameter is measured; from the relationship of the radius wear and the flank wear on a circumferential cutting edge, the flank wear is obtained. The improved watershed algorithm based on the marked grayscale gradient image, the pixel level positioning algorithm based on Sobel operator, and the sub-pixel level positioning algorithm based on the grayscale moment are adopted for image edge detection. The performed experiments validate that the proposed image-based method is an effective way for measuring wear of the circumferential cutting edge of a milling cutter.

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Funding

This study is supported by the Jiangsu Provincial Key Research and Development Program (Grant No. BE2020779) and National Key Laboratory of Science and Technology on Helicopter Transmission (Grant No. HTL-O-21G10).

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Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Ruijun Liang, Yang Li, Lei He & Weifang Chen

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  1. Ruijun Liang
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  2. Yang Li
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  3. Lei He
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  4. Weifang Chen
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Contributions

Ruijun Liang designed the project and wrote the manuscript. Yang Li and Lei He performed the experiments. All authors participated in the interpretation of the results.

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Correspondence to Ruijun Liang.

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Liang, R., Li, Y., He, L. et al. A novel image-based method for wear measurement of circumferential cutting edges of end mills. Int J Adv Manuf Technol 120, 7595–7608 (2022). https://doi.org/10.1007/s00170-022-09215-y

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