Research On Grinding Wheel Wear Detection System And Method Based On Digital Image Processing

Grinding wheel is the main tool for precision and ultra-precision grinding,and the status of grinding wheel directly affects the quality of ground workpieces,economic cost and production efficiency.The status of grinding wheel is affected by factors such as the topography of wheel,processing environment,and process parameters.Among them,the topography of wheel is the main factor affecting its grinding performance.Mature commercial equipment that are used to collect the topography of grinding wheel are often expensive,take a long time to detect,and cannot meet the requirements of rapid detection.Therefore,a low-cost and easy-to-operate grinding wheel topography acquisition system was developed in this paper,which can extract the surface topography and process image rapidly.The main research work of this paper is as follows:(1)A shape acquisition system based on the principle of optical imaging is designed.The main hardware components include an industrial camera,a continuous zoom stereo microscope head,a metallographic objective lens,and a built-in external coaxial light source.The system can achieve continuous zoom adjustment in the range of 125X?810X,which is suitable for the image acquisition of grinding wheel with a particle size of more than 40?m,while maintaining high accuracy while reducing costs.(2)The grinding mechanism of wheel and the evaluation index of surface topography were explored,and the change of wear flats was proposed to represent the grinding performance of grinding wheel during the grinding process.Grinding experiments of resin-bonded diamond grinding wheels with different particle sizes were carried out and the experimental data were processed and analyzed.The experimental results show that the wear flats can characterize the change of the surface topography of grinding wheel,and can be used as an index to evaluate the change of grinding performance.(3)De-noising,image segmentation,and morphological processing were performed on the collected images using digital image processing technology.Comparing the segmentation effects of maximum inter-class variance in the threshold segmentation method,the iterative method,and the one-dimensional maximum entropy method,the one-dimensional maximum entropy threshold method is finally selected for image segmentation.Morphological processing is performed on the image based on the region growing method and the Two-Pass algorithm,which improves the extraction accuracy of abrasive wear flats.(4)Based on Microsoft Visual Studio 2012 development platform,using C#/C++language mixed programming,developed a set of grinding wheel wear condition evaluation software that based on digital image processing.The image acquisition and image processing functions are integrated,which can realize the collection and the processing of topographic images simultaneously.The system built in this paper can realize the rapid acquisition of surface topography images of resin bonded diamond grinding wheel,which can reduce the cost while ensuring the accuracy of the detection.Meanwhile,using the abrasive wear flats as an index to evaluate the wear status of grinding wheel can well characterize the grinding performance.