A new tool wear compensation method based on real-time estimation of material removal volume in micro-EDM

Monitoring Method of High-speed Tool Wear Level based on Machine Vision

“…The amount of different material tool front and rear flank wear were obtained in the similar method according to the cutting condition and high speed cutting tool wear mechanism, which provide an important basis for tool radius compensation through modifying the corresponding bias parameters [20]. The tool should be replaced when the wear level is located at the end of the M level (medium), preventing that the tool enters into the H level (high).…”

“…In the image preprocess, first of all, the clarity of the target's original image must be maintained and without destroying the useful information such as contour and edge, secondly, the noise interference was eliminated and the background unrelated to the object was removed. The acquired high-speed machining tool's image is shown in Figure 7.The median filter method and enhanced resolution, mean filter and image segmentation method in reference [20] was adopted to remove or reduce the noise and interference of the blade image because of complicated tool image background in high-speed machining. The tool's image adopted median filter method is shown in Figure 8 and the tool's image after histogram equalization is shown in Figure 9.…”

A New Measurement Method of Relative Volume Wear Ratio Based on Discharge Debris Composition Analysis in Micro-EDM

“…The microgroove is machined with overcut, when is greater than the actual value; conversely, the microgroove is machined with undercut, when is less than the actual value [16]. Thus, the microgroove is machined precisely only when is equal to the actual value, and the RVWR can be validated according to the accuracy of depth of machined microgroove.…”

“…Bleys et al [15] presented real-time tool wear sensing and compensation in layer-bylayer EDM milling based on discharge pulse evaluation to estimate electrode wear online with a mathematical model of the sparking frequency. Aligiri et al [16] also presented a compensation method to estimate material removal volume by counting the number of discharge pulses. To improve machining efficiency, Yan et al [17] proposed an electrode wear compensation method in micro-EDM using an optical measurement of the tool electrode.…”

“…To improve machining efficiency, Yan et al [17] proposed an electrode wear compensation method in micro-EDM using an optical measurement of the tool electrode. However, the proposed compensation approaches [15][16][17] heavily rely on sophisticated monitoring systems or optical measure systems, which limit their practical applications.…”