Estimation of cutting forces and surface roughness for hard turning using neural networks

Metal cutting mechanics is quite complicated and it is very difficult to develop a comprehensive model which involves all cutting parameters affecting machining variables. In this study, machining variables such as cutting forces and surface roughness are measured during turning at different cutting parameters such as approaching angle, speed, feed and depth of cut. The data obtained by experimentation is analyzed and used to construct model using neural networks. The model obtained is then tested with the experimental data and results are indicated.     

人工神经网络预测刀具磨损和切削力

刀具磨损和切削力预测与控制是切削加工过程中需要考虑的重要问题.本文介绍了利用人工神经网络模型预测刀具磨损和切削力的步骤并且针对产生误差的因素进行分析.首先将切削速度、切削深度、切削时间、主轴转速和不同频带的能量值通过归一化法处理,作为输入特征值,对改进的神经网络模型进行训练.然后利用训练完成的神经网络模型预测刀具磨损和切削力.结果表明:神经网络模型能够综合考虑加工过程中更多的影响因素,与经验公式结果对比,具有更高的预测精度.研究结果表明神经网络模型预测刀具磨损和切削力具有可行性和准确性,为刀具结构的优化及加工参数的选择提供了依据.     

Optimum design of structures by an improved genetic algorithm using neural networks

Optimum design of large-scale structures by standard genetic algorithm (GA) makes the computational burden of the process very high. To reduce the computational cost of standard GA, two different strategies are used. The first strategy is by modifying the standard GA, called virtual sub-population method (VSP). The second strategy is by using artificial neural networks for approximating the structural analysis. In this study, radial basis function (RBF), counter propagation (CP) and generalized regression (GR) neural networks are used. Using neural networks within the framework of VSP creates a robust tool for optimum design of structures.     

Structure minimization using the impact factor in neural networks

Despite many advances, the problem of determining the proper size of a neural network is important, especially for its practical implications in such issues as learning and generalization. Unfortunately, it is not usually obvious which size is best; a system that is too small will not be able to learn the data, while one that is just big enough may learn very slowly and be very sensitive to initial conditions and learning parameters. There are two types of approach to determining the network size: pruning and growing. Pruning consists of training a network which is larger than necessary, and then removing unnecessary weights/nodes. Here, a new pruning method is developed, based on the penalty-term method. This method makes the neural networks good for generalization, and reduces the retraining time needed after pruning weights/nodes. This work was presented, in part, at the 6th International Symposium on Artificial Life and Robotics, Tokyo, Japan, January 15–17, 2001.     

Servo controller design using neural networks

The dynamics of a physical plant may be difficult to express as concise mathematical equations. In practice there exist uncertainties that cannot be modeled with the system equations. Hence, robustness against system uncertainties is essential in a control system design. In this article, multilayered neural networks (MNNs) are used to compensate for model uncertainties of a dynamical system. Neural network models are used along with a classical linear servo controller derived from the linear state space equations. These models are trained so that system uncertainties are compensated. The design of a servo system indicates the enhanced performance of the neural-network-based servo controller as compared to the classical servo controller.     

Aeromagnetic compensation using neural networks

Airborne magnetic surveys in geophysical exploration can be subject to interference effects from the aircraft. Principal sources are the permanent magnetism of various parts of the aircraft, induction effects created by the earth's magnetic field and eddy-current fields produced by the aircraft's manoeuvres. Neural networks can model these effects as functions of roll, pitch, heading and their time derivatives, together with vertical acceleration, charging currents to the generator, etc., without assuming an explicit physical model. Separation of interference effects from background regional and diurnal fields can also be achieved in a satisfactory way.     

The experimental investigation of the effects of uncoated,PVD- and CVD-coated cemented carbide inserts and cutting parameters on surface roughness in CNC turning and its prediction using artificial neural networks

In this study the machining of AISI 1030 steel (i.e. orthogonal cutting) uncoated, PVD- and CVD-coated cemented carbide insert with different feed rates of 0.25, 0.30, 0.35, 0.40 and 0.45 mm/rev with the cutting speeds of 100, 200 and 300 m/min by keeping depth of cuts constant (i.e. 2 mm), without using cooling liquids has been accomplished. The surface roughness effects of coating method, coating material, cutting speed and feed rate on the workpiece have been investigated. Among the cutting tools—with 200 mm/min cutting speed and 0.25 mm/rev feed rate—the TiN coated with PVD method has provided 2.16 μm, TiAlN coated with PVD method has provided 2.3 μm, AlTiN coated with PVD method has provided 2.46 μm surface roughness values, respectively. While the uncoated cutting tool with the cutting speed of 100 m/min and 0.25 mm/rev feed rate has yielded the surface roughness value of 2.45 μm. Afterwards, these experimental studies were executed on artificial neural networks (ANN). The training and test data of the ANNs have been prepared using experimental patterns for the surface roughness. In the input layer of the ANNs, the coating tools, feed rate (f) and cutting speed (V) values are used while at the output layer the surface roughness values are used. They are used to train and test multilayered, hierarchically connected and directed networks with varying numbers of the hidden layers using back-propagation scaled conjugate gradient (SCG) and Levenberg–Marquardt (LM) algorithms with the logistic sigmoid transfer function. The experimental values and ANN predictions are compared by statistical error analyzing methods. It is shown that the SCG model with nine neurons in the hidden layer has produced absolute fraction of variance (R²) values about 0.99985 for the training data, and 0.99983 for the test data; root mean square error (RMSE) values are smaller than 0.00265; and mean error percentage (MEP) are about 1.13458 and 1.88698 for the training and test data, respectively. Therefore, the surface roughness value has been determined by the ANN with an acceptable accuracy.     

Force-torque based on-line tool wear estimation system for CNC milling of Inconel 718 using neural networks

In a modern machining system, tool condition monitoring systems are needed to get higher quality production and to prevent the downtime of machine tools due to catastrophic tool failures. Also, in precision machining processes surface quality of the manufactured part can be related to the conditions of the cutting tools. This increases industrial interest for in-process tool condition monitoring (TCM) systems. TCM supported modern unmanned manufacturing process is an integrated system composed of sensors, signal processing interface and intelligent decision making strategies. This study includes key considerations for development of an online TCM system for milling of Inconel 718 superalloy. An effective and efficient strategy based on artificial neural networks (ANN) is presented to estimate tool flank wear. ANN based decision making model was trained by using real time acquired three axis (F_x, F_y, F_z) cutting force and torque (M_z) signals and also with cutting conditions and time. The presented ANN model demonstrated a very good statistical performance with a high correlation and extremely low error ratio between the actual and predicted values of flank wear.     

Portfolio selection using neural networks

In this paper we apply a heuristic method based on artificial neural networks (NN) in order to trace out the efficient frontier associated to the portfolio selection problem. We consider a generalization of the standard Markowitz mean-variance model which includes cardinality and bounding constraints. These constraints ensure the investment in a given number of different assets and limit the amount of capital to be invested in each asset. We present some experimental results obtained with the NN heuristic and we compare them to those obtained with three previous heuristic methods. The portfolio selection problem is an instance from the family of quadratic programming problems when the standard Markowitz mean-variance model is considered. But if this model is generalized to include cardinality and bounding constraints, then the portfolio selection problem becomes a mixed quadratic and integer programming problem. When considering the latter model, there is not any exact algorithm able to solve the portfolio selection problem in an efficient way. The use of heuristic algorithms in this case is imperative. In the past some heuristic methods based mainly on evolutionary algorithms, tabu search and simulated annealing have been developed. The purpose of this paper is to consider a particular neural network (NN) model, the Hopfield network, which has been used to solve some other optimisation problems and apply it here to the portfolio selection problem, comparing the new results to those obtained with previous heuristic algorithms.     

Optimization of type-2 fuzzy weights in backpropagation learning for neural networks using GAs and PSO

In this paper the optimization of type-2 fuzzy inference systems using genetic algorithms (GAs) and particle swarm optimization (PSO) is presented. The optimized type-2 fuzzy inference systems are used to estimate the type-2 fuzzy weights of backpropagation neural networks. Simulation results and a comparative study among neural networks with type-2 fuzzy weights without optimization of the type-2 fuzzy inference systems, neural networks with optimized type-2 fuzzy weights using genetic algorithms, and neural networks with optimized type-2 fuzzy weights using particle swarm optimization are presented to illustrate the advantages of the bio-inspired methods. The comparative study is based on a benchmark case of prediction, which is the Mackey-Glass time series (for τ = 17) problem.     

Solving TSP by using Lotka–Volterra neural networks

This paper proposes a new approach to solve traveling salesman problem (TSP) by using a class of Lotka–Volterra neural networks (LVNN) with global inhibition. Some stability criteria that ensure the convergence of valid solutions are obtained. It is proved that an equilibrium state is stable if and only if it corresponds to a valid solution of the TSP. Thus, a valid solution can always be obtained whenever the network convergence to a stable state. A set of analytical conditions for optimal settings of LVNN is derived. Simulation results illustrate the theoretical analysis.     

Multi-class pattern classification using neural networks

Multi-class pattern classification has many applications including text document classification, speech recognition, object recognition, etc. Multi-class pattern classification using neural networks is not a trivial extension from two-class neural networks. This paper presents a comprehensive and competitive study in multi-class neural learning with focuses on issues including neural network architecture, encoding schemes, training methodology and training time complexity. Our study includes multi-class pattern classification using either a system of multiple neural networks or a single neural network, and modeling pattern classes using one-against-all, one-against-one, one-against-higher-order, and P-against-Q. We also discuss implementations of these approaches and analyze training time complexity associated with each approach. We evaluate six different neural network system architectures for multi-class pattern classification along the dimensions of imbalanced data, large number of pattern classes, large vs. small training data through experiments conducted on well-known benchmark data.     

Planning grasps for industrial robotized applications using neural networks

The present paper proposes a computer-aided module for the detection of grasps of 3D objects by using artificial neural networks. This module considers the grasps performed by the most common classes of grippers used in industrial applications: two-jaw grippers, three-jaw grippers, magnetic grippers, vacuum grippers and expandable grippers. The neural networks are properly tailored and trained in order to evaluate and compare the different grasping alternatives according to geometrical and technological aspects of object surfaces. A case study is also discussed in order to point out the performances of this methodology.     

Hierarchical multi-label classification using local neural networks

Hierarchical multi-label classification is a complex classification task where the classes involved in the problem are hierarchically structured and each example may simultaneously belong to more than one class in each hierarchical level. In this paper, we extend our previous works, where we investigated a new local-based classification method that incrementally trains a multi-layer perceptron for each level of the classification hierarchy. Predictions made by a neural network in a given level are used as inputs to the neural network responsible for the prediction in the next level. We compare the proposed method with one state-of-the-art decision-tree induction method and two decision-tree induction methods, using several hierarchical multi-label classification datasets. We perform a thorough experimental analysis, showing that our method obtains competitive results to a robust global method regarding both precision and recall evaluation measures.     

Training neural networks by stochastic optimisation

We present a stochastic learning algorithm for neural networks. The algorithm does not make any assumptions about transfer functions of individual neurons and does not depend on a functional form of a performance measure. The algorithm uses a random step of varying size to adapt weights. The average size of the step decreases during learning. The large steps enable the algorithm to jump over local maxima/minima, while the small ones ensure convergence in a local area. We investigate convergence properties of the proposed algorithm as well as test the algorithm on four supervised and unsupervised learning problems. We have found a superiority of this algorithm compared to several known algorithms when testing them on generated as well as real data.     

Parametric system identification using neural networks

Neural networks are used in many applications such as image recognition, classification, control and system identification. However, the parameters of the identified system are embedded within the neural network architecture and are not identified explicitly. In this paper, a mathematical relationship between the network weights and the transfer function parameters is derived. Furthermore, an easy-to-follow algorithm that can estimate the transfer function models for multi-layer feedforward neural networks is proposed. These estimated models provide an insight into the system dynamics, where information such as time response, frequency response, and pole/zero locations can be calculated and analyzed. In order to validate the suitability and accuracy of the proposed algorithm, four different simulation examples are provided and analyzed for three-layer neural network models.     

SR-30 turbojet engine real-time sensor health monitoring using neural networks,and Bayesian belief networks

This paper describes the use of artificial intelligence-based techniques for detecting and isolating sensor failures in a turbojet engine. Specifically, three artificial intelligence (AI) techniques are employed: artificial neural networks (NNs), statistical expectations, and Bayesian belief networks (BBNs). These techniques are combined into an overall system that is capable of distinguishing between sensor failure and engine failure—a critical capability in the operation of turbojet engines. The turbojet engine used in this study is an SR-30 developed by Turbine Technologies. Initially, NNs were designed and trained to recognize sensor failure in the engine. The increased random noise output from failing sensors was used as the key indicator. Next, a Bayesian statistical method was used to recognize sensor failure based on the bias error occurring in the sensors. Finally, a BBN was developed to interpret the results of the NN and statistical evaluations. The BBN determines whether single or multiple sensor failures signify engine failure, or whether sensor failures represent separate, unrelated incidences. The BBN algorithm is also used to distinguish between bias and noise errors on sensors used to monitor turbojet performance. The overall system is demonstrated to work equally well during start-up and main-stage operation of the engine. Results show that the method can efficiently detect and isolate single or multiple sensor failures within this dynamic environment.     

Structure optimization of neural networks for evolutionary design optimization

We study the use of neural networks as approximate models for the fitness evaluation in evolutionary design optimization. To improve the quality of the neural network models, structure optimization of these networks is performed with respect to two different criteria: One is the commonly used approximation error with respect to all available data, and the other is the ability of the networks to learn different problems of a common class of problems fast and with high accuracy. Simulation results from turbine blade optimizations using the structurally optimized neural network models are presented to show that the performance of the models can be improved significantly through structure optimization.We would like to thank the BMBF, grant LOKI, number 01 IB 001 C, for their financial support of our research.     

Prediction of vehicle reliability performance using artificial neural networks

Product development is an important but also dynamic, lengthy and risky phase in the life of a new product. The optimisation of the product development phase through extensive knowledge of the involved procedures is believed to reduce the risks and improve the final product quality. Artificial intelligence and expert systems have been used successfully in optimising the development phase of some new products as it will be demonstrated by the first sections of this publication. This paper presents the first module of an expert system, a neural network architecture that could predict the reliability performance of a vehicle at later stages of its life by using only information from a first inspection after the vehicle’s prototype production. The paper demonstrates how a tool like neural networks can be designed and optimised for use in reliability performance predictions. Also, this paper presents an optimisation methodology that enabled the neural network to deal with the limited amount of available training data, common during new product development, and to finally achieve acceptable prediction performance with small error. A case example is presented to demonstrate the methodology.