AI-based image evaluation Handling and defect inspection of indexable inserts

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Indexable inserts require high-precision manufacturing to ensure their performance and durability. Any small defects can significantly impact their effectiveness and lead to high costs. A German company, Xactools, has developed an advanced AI-driven inspection system for a Scandinavian manufacturer to enhance the quality control of these inserts.

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.