To address the issues of low efficiency and limited precision in wear detection for mechanical scribing tools, a machine vision-based inspection methodology was proposed to achieve cost-effective, high-efficiency wear monitoring with micron-level measurement accuracy. Firstly, the image of the cutting tool tip was obtained by an industrial camera, and then image cropping and grayscale processing were carried out on it. Subsequently, three methods, namely median filtering, Gaussian filtering and mean filtering, were adopted to filter and compare the grayscale images respectively. The filtered images were sharened and the edge features were optimized by selecting the best ones. Finally, the edge of the scratch tool image was extracted based on the Canny sub-pixel edge detection method. Results indicate that the main wear areas of the scribing tool are the primary scribing edge and flank face, with wear lengths of 361.1 μm and 43.7 μm respectively, while wear depth values gradually decrease to 0 μm along the direction away from the tool tip, with average wear depth values of 3.1 μm and 2.9 μm in these two areas. The maximum wear depth is concentrated at the tool tip with a value of 11 μm.
综上所述,目前机器视觉在车削、铣削、拉削等刀具的磨损检测方面均取得了不错的成果,但是机器视觉技术在此类加工方式中的检测的磨损区域物理尺度主要集中在几十到几百微米之间。机械刻划属于超精密加工,刻划深度通常在几微米以内,进而刀具磨损深度往往处于更小的尺寸范围。金刚石刻划刀具的磨损检测通常借助扫描电子显微镜(scanning electron microscope,SEM)检测[11],但是SEM设备昂贵,使用成本高,效率低。因此,现开展基于机器视觉刻划刀具的磨损检测研究,旨在探索一种经济高效、高精度的刻划刀具磨损检测方法。首先,由工业相机获取刻划刀具刀尖图像。其次,使用图像处理算法对图像进行优化处理。最后,获取刀具边缘并计算刀具磨损深度。
DrouilletC, KarandikarJ, NathC, et al. Tool life predictions in milling using spindle power with the neural network technique[J]. Journal of Manufacturing Processes, 2016, 22: 161-168.
[2]
LiuD, LiuZ, ZhaoJ, et al. Tool wear monitoring through online measured cutting force and cutting temperature during face milling Inconel 718[J]. The International Journal of Advanced Manufacturing Technology, 2022, 122(2): 729-740.
LiYang, LiLiang, ChenNi, et al. Design and research of tool wear condition monitoring ring based on MEMS sensors[J]. Tool Engineering, 2022, 56(7): 3-7.
YuGuangning, ShiHuinan, ChiJie, et al. Online monitoring method of diamond roller wear based on built-in acoustic emission device[J]. Science Technology and Engineering, 2024, 24(26): 11253-11262.
[7]
SuJ C, HuangC K, TangY S. An automated flank wear measurement of microdrills using machine vision[J]. Journal of Materials Processing Technology, 2006, 180(1/3): 328-335.
[8]
LoizouJ, TianW, RobertsonJ, et al. Automated wear characterization for broaching tools based on machine vision systems[J]. Journal of Manufacturing Systems, 2015, 37: 558-563.
[9]
DaiY, ZhuK. A machine vision system for micro-milling tool condition monitoring[J]. Precision Engineering, 2018, 52: 183-191.
[10]
HouQ, SunJ, HuangP. A novel algorithm for tool wear online inspection based on machine vision[J]. The International Journal of Advanced Manufacturing Technology, 2019, 101: 2415-2423.
DengXiaopeng, HuXiaofeng. Machine vision-based method for tool wear detection in milling and turning[J]. Combined Machine Tools and Automation Technology, 2022(10): 105-108,114.
[13]
HuS, WenH, ZhangZ, et al. Attention mechanism based CNC milling cutter wear detection using machine vision[C]// 2023 29th International Conference on Mechatronics and Machine Vision in Practice (M2VIP). New York: IEEE, 2023: 1-6.
ZhangBaoqing, MaQun, AnYangjie, et al. Research on tool wear of aluminum film with mechanical scratching layer structure[J]. Manufacturing Technology & Machine Tool, 2024(2): 111-116.
[16]
ChaY J, YouK, ChoiW. Vision-based detection of loosened bolts using the Hough transform and support vector machines[J]. Automation in Construction, 2016, 71: 181-188.
LiYadi, HuangHaibo, LiXiangpeng, et al. Nighttime lane detection based on Canny operator and Hough transform[J]. Science Technology and Engineering, 2016, 16(31): 234-237, 242.
CaiJing, WangKai, LiYue, et al. Infrared image airport runway water identification method based on the fusion algorithm of Canny operator + fuzzy C-means clustering[J]. Science Technology and Engineering, 2024, 24(28): 12382-12390.
HuangWenwen, PengXiaohong, LiLiyuan, et al. Review on camera calibration methods and research progress[J]. Laser & Optoelectronics Progress, 2023, 60(16): 9-19.
ZhengXiaoyu, ZhouHuixing, WangShun, et al. Door and window hole size measurement based on laser point calibration and machine vision[J]. Science Technology and Engineering, 2022, 22(15): 6204-6209.