Machine-vision-based identification of broken inserts in edge profile milling heads

This paper presents a reliable machine vision system to automatically detect inserts and determine if they are broken. Unlike the machining operations studied in the literature, we are dealing with edge milling head tools for aggressive machining of thick plates (up to 12 centimetres) in a single pass. The studied cutting head tool is characterised by its relatively high number of inserts (up to 30) which makes the localisation of inserts a key aspect. The identification of broken inserts is critical for a proper tool monitoring system. In the method that we propose, we first localise the screws of the inserts and then we determine the expected position and orientation of the cutting edge by applying some geometrical operations. We compute the deviations from the expected cutting edge to the real edge of the inserts to determine if an insert is broken. We evaluated the proposed method on a new dataset that we acquired and made public. The obtained result (a harmonic mean of precision and recall 91.43%) shows that the machine vision system that we present is effective and suitable for the identification of broken inserts in machining head tools and ready to be installed in an on-line system. HighlightsA novel machine-vision-based method that detects broken inserts in milling heads.Unlike other methods, this approach does not require comparison to reference images.We demonstrate its effectiveness on a new data set of 144 images with 180 inserts.It is very efficient and it can be used without delaying any machining operations.