Application of Image Processing for Tool Flank Wear Measurement and Optimization Using the Taguchi Method

In any machining, process parameters are optimized to obtain a better output with optimum input. Tool flank wear is one of the machinability parameters that significantly affect the cost of production and surface quality. In this study, turning procedure is carried out on Inconel 718, utilizing a micro-hole pattern on the rake face of the insert coupled with tungsten disulfide (WS₂) solid lubricant as coolant. Process parameters are optimized using the Taguchi method to minimize flank wear. The result of optimization revealed that a cutting speed of 140 m/min, feed rate of 0.1 mm/rev, and depth of cut of 1.5 mm were ideal. Tool flank wear is often obtained using microscopic and SEM analysis methods. For this study, image processing steps are used to evaluate flank wear. The image of the patterned insert is the input, and a sequence of operations is carried out with MAT lab to obtain the flank wear. To validate the result, the optimized flank wear value obtained from Image processing is compared through optical microscope and noticed that the error is minimum. The result revealed that image processing is a reliable method to measure tool flank wear accurately and the optimized value using Taguchi leads to effective machining performance.