Novel and Cost-Effective CNC Tool Condition Monitoring Through Image Processing Techniques

Abstract This paper introduces a novel and effective approach for tool condition monitoring (TCM) in CNC machining through the application of image processing techniques. Utilizing a consumer-grade camera capable of recording videos at 60 frames per second, the study demonstrates a cost-effective method for detecting tool breakage and identifying edge fractures. Basic image processing techniques, including frame extraction, background subtraction, thresholding, and morphological operations, are applied to analyze the captured images and videos. This research not only offers a practical solution to enhance the efficiency and accuracy of CNC machine operations but also aligns with advancements in smart manufacturing and Industry 4.0. Moreover, it paves the way for future research in this area, suggesting potential for further refinement and broader application of such monitoring techniques.