Abstract
Chipping in ceramic cutting inserts during machining can cause detrimental effects on the surface finish quality of the workpiece. Current methods of detecting chipping in ceramic inserts do not compare the minute changes in the workpiece profile in subsequent machining passes. In this work, an effective method of detecting chipping in ceramic inserts by analysing the workpiece surface profile using cross-correlation is proposed. In this method, the sub-pixel edge location method was used to extract the surface profile captured using a digital camera. Surface profiles corresponding to subsequent machining passes were cross-correlated at three different sections of the workpiece. An abrupt drop in the correlation coefficient was observed in the middle and end sections of the workpiece after the fifth machining pass, thus providing a reliable measure of tool chipping.
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