Indexable inserts are interchangeable cutting tools that are indispensable in various industrial applications, especially in metalworking. They are used as cutting material carriers for machining metals, plastics or wood. Their manufacture requires high-precision production processes to ensure an exact geometry and perfect surface finish. Even minimal deviations affect not only the service life but also the performance of the cutting insert. The smallest defects that are invisible to the human eye can cause immense damage, for example when milling or cutting high-quality components – including consequential costs. Careful quality control is essential to ensure that only flawless indexable inserts leave the production process and meet the high requirements in terms of durability and reliability. A flagship project by automation and measurement technology specialist Xactools from Germany demonstrates how artificial intelligence can help visual inspection make quantum leaps. The German medium-sized company has developed a fully automated handling and inspection system for a global manufacturer of indexable inserts based in Scandinavia, in which the DENKnet solution for AI-based image evaluation plays a decisive role and sets new standards in terms of performance, zero-defect production and speed.
Around 1.2 million indexable inserts leave the Scandinavian company’s production halls every week, which have to guarantee the highest possible process reliability and maximum productivity in the metalworking, automotive and aerospace industries, for example. They are manufactured using the sintering process, in which powdered metals, hard metals and other materials are pressed into the desired shape and then sintered, i.e. bonded together under heat and pressure. The strong and robust structure created in this way makes it possible to combine materials with different properties in order to achieve the desired cutting and wear resistance properties. After the sintering process, the edges of the indexable inserts are rounded and ground, and their surfaces are blasted, ground and coated.
As versatile as the areas of application of the small tool parts are, so varied are their properties and geometries. This manufacturer alone has around 2,800 products in its portfolio, which can be divided into almost one hundred geometry families. The aim was to automate handling and defect inspection for all of these.
But in addition to the visual appearance, it is also about the insert geometry. Categories such as triangle, rectangle, rhombus or square can be found in countless variations due to the smallest deviations and are therefore divided into manageable subcategories, so-called geometry families. Xactools made the pre-selection for the training of the meshes; almost one hundred geometry families were defined and then taught in by the manufacturer itself.
A total of eight cameras with resolutions between 5 and 30 megapixels provide live images of the indexable inserts, which are positioned by magnetic or interchangeable grippers.
To prevent this from happening during the production process and to exercise the greatest possible caution, the system also records images of the contour and position of the panels after inspecting the
It can see exactly where and in which rotational position the indexable insert is positioned so that the magnetic gripper can finally place it on pin pallets. To ensure this, the gripper, to which the indexable insert is attached, moves over a camera that detects the exact position of the hole from below. At the same time, the contour of the insert and the outer edge of the gripper are detected in order to correct the position of the indexable insert and hit the pin if necessary. In addition, each individual pin position is detected in order to recognize bent and broken pins so that they are not palletized in the first place.
Filed Under: Automotive, Sensor Tips