In machining, the condition of a cutting tool directly affects processing quality and efficiency. Regular inspection helps identify wear or damage early, preventing unexpected issues during machining and improving productivity and product quality. Below are several common tool inspection methods:

1. Visual Inspection
Method:
Observe the cutting edge and surface of the tool to check for obvious wear, chipping, cracks, or edge deformation.
A magnifying glass or microscope can be used to examine small cracks or fine wear more closely.
Advantages:
Fast, simple, economical, and requires no special equipment.
Helps identify obvious wear and edge damage promptly.
Disadvantages:
Cannot accurately measure minor wear or determine wear degree.
Highly dependent on operator experience.

2. Measuring Instruments Inspection
Method:
Use tool measuring instruments (tool microscopes, projectors, laser measuring devices) to precisely measure geometric parameters, wear amounts, and angles.
By measuring flank wear, edge radius changes, etc., the wear condition can be accurately evaluated.
Advantages:
Provides highly accurate measurements and detects micro-wear unrecognizable by the naked eye.
Disadvantages:
Requires specialized equipment and higher cost.
More complex operation and requires training.

3. Online Monitoring
Method:
Use the machine’s built-in monitoring system to check wear in real time through cutting force, vibration, acoustic emission, or spindle current analysis.
Sensors collect signal variations to determine wear or breakage.
Advantages:
Real-time monitoring helps detect issues early, reducing unexpected failures.
Improves automation and reduces manual intervention.
Disadvantages:
Requires dedicated sensors and higher initial investment.
Accuracy may be affected by environmental noise.

4. Tool Life Prediction System
Method:
Predict remaining tool life through analysis of cutting parameters, material characteristics, cutting force, temperature, and historical data models.
Provides recommendations for tool replacement.
Advantages:
Enables predictive maintenance, preventing excessive or premature tool changes.
Improves production continuity and reduces tool cost.
Disadvantages:
Requires large historical datasets and complex models.
Precision may drop in non-standard machining conditions.

5. Tactile Inspection
Method:
Gently touch the cutting edge with a finger to feel burrs, chipping, or deformation and judge edge smoothness and sharpness.
Advantages:
Simple, intuitive, and economical.
Disadvantages:
Highly subjective and reliant on operator experience.
Cannot detect micro-wear or provide accurate measurements.

6. Microscopic Observation
Method:
Use a tool microscope or digital microscope to observe wear, cracks, and micro-chipping in high detail.
Advantages:
Reveals small defects not visible to the naked eye.
Useful for quality assessment and research on wear mechanisms.
Disadvantages:
Requires expensive equipment and complex operation.
Not suitable for fast inspection of large quantities.

7. Magnetic Particle or Dye Penetration Testing
Method:
Use magnetic powder or dye to reveal surface cracks through visible marks.
Commonly used for hard tools like carbide tools to detect fine cracks.
Advantages:
Highly effective for detecting surface cracks without damaging the tool.
Disadvantages:
Requires professional equipment and trained operators.
Not suitable for general wear inspection.

8. Sound Monitoring
Method:
Listen to the cutting sound during machining. Worn or chipped tools often produce harsh or abnormal sounds.
Advantages:
Quick and intuitive, suitable for on-site large-volume production.
Disadvantages:
Highly subjective and influenced by operator experience.
Background noise may affect accuracy.

Each method has its own advantages and limitations. The appropriate inspection method should be selected based on machining requirements, production conditions, and tool type to ensure tools operate in optimal condition and improve machining quality and efficiency.