Robust and Fast Monitoring Method of Micro-Milling Tool Wear Using Image Processing

• The proposed image-based method robustly handles uneven illumination and arbitrary tool orientation in micro-milling tool wear monitoring. • The algorithm restores lost pixels during segmentation, accurately extracting wear areas despite challenging imaging conditions. • The method exhibits low computational complexity and fast execution, significantly reducing in-situ detection time. • This approach enhances tool condition monitoring, potentially reducing downtime and production costs in micro-milling.