Development of the Machining Optimization System for NC Lathe

This paper presents a method for measuring minor flank wear width using image processing with a camera mounted on an NC lathe. The flank wear width is a key determinant of tool life, making its prediction an important area of research. Additionally, with the increasing adoption of multitasking machines and the declining workforce in the manufacturing industry, it is crucial to develop a machining optimization system that can automatically set cutting conditions and determine tool life. Therefore, we developed a system for shooting minor flank face mounted on an NC lathe. And, using this system, we studied a method to accurately measure the minor flank wear width when turning S45C with a CVD coated carbide tool using image processing technology. As a result, it was found that wear areas can be effectively detected by illumination the tool from two different directions. Furthermore, applying of luminance correction enhances the contrast between worn and unworn areas, facilitating easier detection. By filling holes in the processed image and subtracting the cutting edge from the extracted gap between the cutting edge and the worn area, we successfully measured minor flank wear width from the cutting edge. Examination of the applicability of the minor flank wear width measurement revealed that images equivalent to those obtained by the conventional method could be acquired, and the minor flank wear width could be measured with an error of about 10 μm. These results demonstrate the high adaptability and effectiveness of the proposed method.