In single-part and small-batch production, the condition of the tool is currently assessed by machine operators based on experience. This limits the level of automation and ties up costly specialist staff at the machine. In the VisionWear project, Lorenz Hoffmann GmbH, TAM-Tools GmbH (Goldberg brand) and the IFW are researching a system that automatically records and objectively assesses the degree and pattern of wear on end mills without manual intervention.
To this end, the IFW is developing a camera-based measurement setup that is integrated directly into the machining area of the machine tool. By utilising the machine's kinematics, different views of the tool can be captured using a single camera. A machine learning model then segments the worn surfaces on the cutting edges and determines wear-pattern-dependent parameters such as the flank wear land width VB or the chipping area. On this basis, the system assesses the remaining wear allowance and predicts the process-dependent remaining tool life. The tool change point and the next measurement point are thus determined automatically.
The project is funded under the "Central Innovation Programme for SMEs" (ZIM) of the Federal Ministry for Economic Affairs and Climate Action (BMWK). It commenced on 1 March 2026 and will run until 29 February 2028.
Contact:
For further information, please contact Paul Krombach on +49 511 762 18311 or by email at krombach@ifw.uni-hannover.de.
