Tool wear segmentation in blanking processes with fully convolutional networks based digital image processing

Abstract

The extend of tool wear significantly affects blanking processes and has a decisive impact on product quality and productivity. For this reason, numerous scientists have addressed their research to wear monitoring systems in order to identify or even predict critical wear at an early stage. Existing approaches are mainly based on indirect monitoring using time series, which are used to detect critical wear states via thresholds or machine learning models. Nevertheless, differentiation between types of wear phenomena affecting the tool during blanking as well as quantification of worn surfaces is still limited in practice. While time series data provides partial insights into wear occurrence and evolution, direct monitoring techniques utilizing image data offer a more comprehensive perspective and increased robustness when dealing with varying process parameters. However, acquiring and processing this data in real-time is challenging. In particular, high dynamics combined with increasing strokes rates as well as the high dimensionality of image data have so far prevented the development of direct image-based monitoring systems. For this reason, this paper demonstrates how high-resolution images of tools at 600 spm can be captured and subsequently processed using semantic segmentation deep learning algorithms, more precisely Fully Convolutional Networks (FCN). 125,000 images of the tool are taken from successive strokes. Selected images are labeled pixel by pixel according to their wear condition and used to train a FCN (U-Net). The approach presented offers the possibility of spatially monitoring wear in high-speed blanking operations in real-time.