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Date of Award

2013

Document Type

Thesis - Pacific Access Restricted

Degree Name

Master of Science (M.S.)

Department

Engineering Science

First Advisor

Jiancheng Liu

First Committee Member

Cherian Mathews

Second Committee Member

Louise Stark

Third Committee Member

Brian Weick

Abstract

Cutting tools in a manufacturing system play a significant role in metal cutting process. Cutting tools arc consumable. Tool wear affects the outcomes of machining processes such as machined· surface quality and it is normally used as an indicating parameter for tool life. It is crucial to calculate and record the wear size of different cutting tools. The tool wear is classified into many different categories according to its existing location and wear patterns. Flank wear and crater wear are the two most common types of tool wear which are used to assess the tool's life. The measurements of flank and crater wear in cutting tools have been extensively studied. There are still many challenges when these research results are applied practically. Manufacturing industry demands· accurate and rapid methods for the tool wear measurement. There are two primary objectives in this research. The first is to develop a new tool wear measurement technology by using the active contour model based image processing method for the flank wear measurement. A MATLAB program is developed to verify the suggested image processing algorithm. Many cutting experiments were conducted with different tools on a CNC machine tool. The experimental results show that the developed technology is feasible and can be used to measure the tool wear area. It needs to be noted that this method. can only extract the wear area. This method is not able to estimate the depth of the crater wear. The second objective is to develop a method for crater wear measurement by use of developed stereo vision system. This system consists of a single camera with necessary lighting devices and fixtures. A MATLAB based software is developed to estimate and represent the volume of tool wear. The proposed algorithm and feasibility of the system for the crater wear (3D tool wear) is discussed. Its effectiveness is verified in this research.

Pages

103

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