Method for measuring and recording tool wear: A system for measuring the width of wear scratches quickly and accurately has been developed. This system is capable of measuring deep scratches at an affordable price and can be photographed directly on the machine as required. photo. These photos can then be measured and evaluated on a laptop. Every cutting practitioner wants to increase the life of the tool. Graphs are now mainly used to show the productivity of the machining tool and the process of deepening the wear scratch depth (VB) as the service life increases.
1. The method of measurement arises from actual production: The Profactor process shop in Steyr, Austria, has been using the method of measuring wear scratches on fixed microscopes in the field of "manufacturing process". The wear condition will be taken as a photo and can be measured with the aid of graphics processing software. Since the available working space of the microscope is small, it is necessary to loosen the turntable or the full hard metal tool, so it is impossible to ascertain the width of the wear scratch such as an excessively large or too long tool on the deep hole drill. In the past, people mainly used the magnifying glass integrated with the measuring ruler to check. Although the measurement flexibility can be improved, the difference in the operator can lead to inconsistent measurement results. Similar results can show another system to be tested: on the one hand, although the fixed measurement system is economical, the portability is poor; on the other hand, the measurement accuracy of the simple mobile measurement system is low, and the imaging quality is low. Poor, insufficient measurement depth.
Every cutting practitioner wants to increase the life of the tool. Graphs are now mainly used to show the productivity of the machining tool and the process of deepening the wear scratch depth (VB) as the service life increases.
2, the formation process of tool wear: If you need to frequently record the formation process of wear, analyze the formation mechanism of wear requires a new system. The high-definition digital camera (8 megapixels) is equipped with an optical image stabilizer, a newly developed microscope sight and an accessory light source. The universal joint magnetic tripod can be used as a mobile stand and can be directly attached to the machine. If the user needs to optimize the process, the entire system can be placed in a portable container with the necessary spare battery, charger or cleaning device.
Construction of the measuring system: Sesef Merkinger, Profactor, a digital camera equipped with a magnetic tripod, placed directly in front of the turntable milling cutter of the milling machine, said: "The high quality of the picture, the measurement system and the ease of operation of the evaluation software are a big advantage. We repeatedly asked the user and the tool manufacturer during the measurement process whether they needed to provide them with an integrated measurement system package with software."
3, Abrascan wear measurement package performance advantages: wear measurement package "Abrascan" came into being. To date, craftsmen from the aerospace industry, tool manufacturing and scientific instrumentation industries have begun to apply this system in machining. Check and optimize the measurement system, compact and practical:
1) The measurement process is very simple: the first user of the system was encouraged: "All the adjustment parameters have been stored on the camera - clear and sharp photos can be taken five minutes after opening the package.
2) Turntable: Wear and scratch width VB=0.136mm: The measurement procedure is as follows: Fix the digital camera on a magnetic tripod, turn on the camera and light source, fix it near the tool (±2mm), and use the autofocus function to quickly image. With a magnetic tripod it is also possible to make measurements directly on the milling machine without having to remove the tool from the bracket or the spindle. The digital camera has a display that can be rotated at will, allowing you to shoot anywhere. Shooting in C mode (user-defined mode) allows you to store various experience values ​​in advance. For example, you can adjust the appropriate brightness, flash intensity, zoom, exposure index, or shutter speed. Therefore, the user only needs to turn on the digital camera to shoot at any time. Of course, photography enthusiasts can also fine-tune according to different occasions. The rotor pump can transfer the stored pictures to the laptop via the USB cable and evaluate them with the software.
3) The surface is sharp and sharp. The diameter of the ball end mill is 3mm, and the wear scratch width VB is 0.036mm.
With a measurement window of 6.5 x 6.5 mm and 8 million available pixels in a digital camera system, a resolution of up to 2 μm per pixel can be obtained. With a measuring depth of up to 0.4 mm, the system clearly shows the typical wear scratch width (VB of 20μm to 200μm) on the turntable and the scratch width (VB of 10μm to 50μm) on the full hard metal tool. High quality images can be applied directly to the machine to share the cost of purchasing the microscope. The Abrascan system clearly shows the formation of surface wear. However, this system is not suitable for measuring the absolute dimensions of a part because the distortion of the viewing plane can cause angular misalignment and measurement errors.
4) User-friendly measurement software: The evaluation software Abrascan included in the wear measurement package measures distance (D), angle (A) and radius. Click on the "Distance" icon to display the relevant dimensions in millimeters. More distance and angle measurements can also be displayed in a separate picture. Click the right mouse button to copy the relevant data and save it as an Excel spreadsheet file. This greatly simplifies the formation of the wear scratch width. Other auxiliary functions such as brightness, contrast, and grayscale are also available. Because the system is based on Office software, users can get started quickly without additional training.
5) Measurement accuracy: the measurement ruler with a scale of 0.1mm can be scratched, and the measurement result D1=0.014mm
6) Output measurement value: The measurement process can be generated by storing the measurement value in the spreadsheet software. Abrascan can be used to identify extremely small wear marks and make measurements. Therefore, the tool can be optimized. The image of Abrascan shows that the horizontal axis of wear is the chip distance of the tool, in meters; the vertical axis is the wear scratch width VB, in millimeters; the three curves are tools A, B, and C, respectively.
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