{"title":"Tool Condition Monitoring of Ceramic Inserted Tools in High Speed Machining through Image Processing","authors":"Javier A. Dominguez Caballero, Graeme A. Manson, Matthew B. Marshall","volume":116,"journal":"International Journal of Materials and Metallurgical Engineering","pagesStart":1427,"pagesEnd":1435,"ISSN":"1307-6892","URL":"https:\/\/publications.waset.org\/pdf\/10005046","abstract":"Cutting tools with ceramic inserts are often used in the process of machining many types of superalloy, mainly due to their high strength and thermal resistance. Nevertheless, during the cutting process, the plastic flow wear generated in these inserts enhances and propagates cracks due to high temperature and high mechanical stress. This leads to a very variable failure of the cutting tool. This article explores the relationship between the continuous wear that ceramic SiAlON (solid solutions based on the Si3N4 structure) inserts experience during a high-speed machining process and the evolution of sparks created during the same process. These sparks were analysed through pictures of the cutting process recorded using an SLR camera. Features relating to the intensity and area of the cutting sparks were extracted from the individual pictures using image processing techniques. These features were then related to the ceramic insert’s crater wear area.","references":"[1]\tZ. Liu, X. Ai, H. Zhang, Z. Wang, and Y. Wan, \u201cWear patterns and mechanisms of cutting tools in high-speed face milling,\u201d in The 10th International Manufacturing Conf. in China, Journal of Materials Processing Technology, vol. 129, Fujian, China, 2002, pp. 222-226.\r\n[2]\tS. Casto, E. Valvo, V. Ruisi, E. Lucchini, and S. Maschio, \u201cWear mechanism of ceramic tools,\u201d in Wear, vol. 160, 1993, pp. 227-235.\r\n[3]\tA. Altin, M. Nalbant, and A. Taskesen, \u201cThe effects of cutting speed on tool wear and tool life when machining Inconel 718 with ceramic tools,\u201d in Materials & Design, vol. 28, 2007, pp. 2518-2522.\r\n[4]\tSandvik Coromant, \u201cCeramics,\u201d AB Sandvik Coromant, 2010, Available: http:\/\/www.sandvik.coromant.com\/sitecollectiondocuments\/downloads\/global\/brochures\/en-gb\/c-2929-61.pdf.\r\n[5]\tX. Tian, J. Zhao, J. Zhao, Z. Gong, and Y. Dong, \u201cEffect of cutting speed on cutting forces and wear mechanisms in high-speed face milling of Inconel 718 with Sialon ceramic tools,\u201d in The International Journal of Advanced Manufacturing Technology, vol. 69, London: Springer, 2013, pp. 2669-2678.\r\n[6]\tG. Byrne, D. Dornfeld, I. Inasaki, G. Ketteler, W. K\u00f6nig, and R. Teti, \u201cTool Condition Monitoring (TCM) \u2014 The Status of Research and Industrial Application,\u201d in CIRP Annals - Manufacturing Technology, vol. 44, 1995, pp. 541\u2013567.\r\n[7]\tS. Kurada and C. Bradley, \u201cA machine vision system for tool wear assessment,\u201d in Tribology International, vol. 30, 1997, pp. 295\u2013304.\r\n[8]\tR. C. Gonzalez and R. E. Woods, Digital Image Processing: International Edition, 3rd ed. New Jersey: Pearson Prentice Hall, 2010, pp. 23.\r\n[9]\tD.M. D\u2019Addona and R. Teti, \u201cImage Data Processing via Neural Networks for Tool Wear Prediction,\u201d in 8th CIRP Conf. on Electro Physical and Chemical Machining (ISEM XVIII), vol. 12, 2013, pp. 252\u2013257.\r\n[10]\tS. Kurada and C. Bradley, \u201cA review of machine vision sensors for tool condition monitoring,\u201d in Computers in Industry, vol. 34, 1997, pp. 55-72.\r\n[11]\tT. Pfeifer and L. Wiegers, \u201cReliable tool wear monitoring by optimized image and illumination control in machine vision,\u201d in Measurement, vol. 28, 2000, pp. 209-218.\r\n[12]\tT. Teshima, T. Shibasaka, M. Takuma, A. Yamamoto, and K. Iwata \u201cEstimation of Cutting Tool Life by Processing Tool Image Data with Neural Network,\u201d in CIRP Annals - Manufacturing Technology, vol. 42, 1993, pp. 59-62.\r\n[13]\tJ. A. Dominguez Caballero, G. A. Manson, and M. B. Marshall, \u201cOptimal image processing acquisition parameters for a tool condition monitoring system of ceramic inserted tools,\u201d unpublished.\r\n[14]\tJP. Davim, Machining of Hard Materials, New York: Springer Science & Business Media, 2011, pp. 38.\r\n[15]\tW. Grzesik, Advanced Machining Processes of Metallic Materials: Theory, Modelling and Applications, Elsevier, 2008, pp. 163-166.","publisher":"World Academy of Science, Engineering and Technology","index":"Open Science Index 116, 2016"}