Combining shape and contour features to improve tool wear monitoring in milling processes

In this paper, a new system based on combinations of a shape descriptor and a contour descriptor has been proposed for classifying inserts in milling processes according to their wear level following a computer vision based approach. To describe the wear region shape we have proposed a new descriptor called ShapeFeat and its contour has been characterized using the method BORCHIZ that, to the best of our knowledge, achieves the best performance for tool wear monitoring following a computer vision-based approach. Results show that the combination of BORCHIZ with ShapeFeat using a late fusion method improves the classification performance significantly, obtaining an accuracy of 91.44% in the binary classification (i.e. the classification of the wear as high or low) and 82.90% using three target classes (i.e. classification of the wear as high, medium or low). These results outperform the ones obtained by both descriptors used on their own, which achieve accuracies of 88.70 and 80.67% for two and three classes, respectively, using ShapeFeat and 87.06 and 80.24% with B-ORCHIZ. This study yielded encouraging results for the manufacturing community in order to classify automatically the inserts in terms of their wear for milling processes.

Tool wear monitoring using an online, automatic and low cost system based on local texture

In this work we propose a new online, low cost and fast approach based on computer vision and machine learning to determine whether cutting tools used in edge profile milling processes are serviceable or disposable based on their wear level. We created a new dataset of 254 images of edge profile cutting heads which is, to the best of our knowledge, the first publicly available dataset with enough quality for this purpose. All the inserts were segmented and their cutting edges were cropped, obtaining 577 images of cutting edges: 301 functional and 276 disposable. The proposed method is based on (1) dividing the cutting edge image in different regions, called Wear Patches (WP), (2) characterising each one as worn or serviceable using texture descriptors based on different variants of Local Binary Patterns (LBP) and (3) determine, based on the state of these WP, if the cutting edge (and, therefore, the tool) is serviceable or disposable. We proposed and assessed five different patch division configurations. The individual WP were classified by a Support Vector Machine (SVM) with an intersection kernel. The best patch division configuration and texture descriptor for the WP achieves an accuracy of 90.26% in the detection of the disposable cutting edges. These results show a very promising opportunity for automatic wear monitoring in edge profile milling processes.