Tool wear monitoring and selection of optimum cutting conditions with progressive tool wear effect and input uncertainties

One of the big challenges in machining is replacing the cutting tool at the right time. Carrying on the process with a dull tool may degrade the product quality. However, it may be unnecessary to change the cutting tool if it is still capable of continuing the cutting operation. Both of these cases could increase the production cost. Therefore, an effective tool condition monitoring system may reduce production cost and increase productivity. This paper presents a neural network based sensor fusion model for a tool wear monitoring system in turning operations. A wavelet packet tree approach was used for the analysis of the acquired signals, namely cutting strains in tool holder and motor current, and the extraction of wear-sensitive features. Once a list of possible features had been extracted, the dimension of the input feature space was reduced using principal component analysis. Novel strategies, such as the robustness of the developed ANN models against uncertainty in the input data, and the integration of the monitoring information to an optimization system in order to utilize the progressive tool wear information for selecting the optimum cutting conditions, are proposed and validated in manual turning operations. The approach is simple and flexible enough for online implementation.     

Design of neural network-based estimator for tool wear modeling in hard turning

Hard turning with cubic boron nitride (CBN) tools has been proven to be more effective and efficient than traditional grinding operations in machining hardened steels. However, rapid tool wear is still one of the major hurdles affecting the wide implementation of hard turning in industry. Better prediction of the CBN tool wear progression helps to optimize cutting conditions and/or tool geometry to reduce tool wear, which further helps to make hard turning a viable technology. The objective of this study is to design a novel but simple neural network-based generalized optimal estimator for CBN tool wear prediction in hard turning. The proposed estimator is based on a fully forward connected neural network with cutting conditions and machining time as the inputs and tool flank wear as the output. Extended Kalman filter algorithm is utilized as the network training algorithm to speed up the learning convergence. Network neuron connection is optimized using a destructive optimization algorithm. Besides performance comparisons with the CBN tool wear measurements in hard turning, the proposed tool wear estimator is also evaluated against a multilayer perceptron neural network modeling approach and/or an analytical modeling approach, and it has been proven to be faster, more accurate, and more robust. Although this neural network-based estimator is designed for CBN tool wear modeling in this study, it is expected to be applicable to other tool wear modeling applications.     

Digital twin-driven surface roughness prediction and process parameter adaptive optimization

In the process of parts machining, the real-time state of equipment such as tool wear will change dynamically with the cutting process, and then affect the surface roughness of parts. The traditional process parameter optimization method is difficult to take into account the uncertain factors in the machining process, and cannot meet the requirements of real-time and predictability of process parameter optimization in intelligent manufacturing. To solve this problem, a digital twin-driven surface roughness prediction and process parameter adaptive optimization method is proposed. Firstly, a digital twin containing machining elements is constructed to monitor the machining process in real-time and serve as a data source for process parameter optimization; Then IPSO-GRNN (Improved Particle Swarm Optimization-Generalized Regression Neural Networks) prediction model is constructed to realize tool wear prediction and surface roughness prediction based on data; Finally, when the surface roughness predicted based on the real-time data fails to meet the processing requirements, the digital twin system will warn and perform adaptive optimization of cutting parameters based on the currently predicted tool wear. Through the development of a process-optimized digital twin system and a large number of cutting tests, the effectiveness and advancement of the method proposed in this paper are verified. The organic combination of real-time monitoring, accurate prediction, and optimization decision-making in the machining process is realized which solves the problem of inconsistency between quality and efficiency of the machining process.     

Monitoring of tool wear using measured machining forces and neuro-fuzzy modelling approaches during machining of GFRP composites

The challenges of machining, particularly milling, glass fibre-reinforced polymer (GFRP) composites are their abrasiveness (which lead to excessive tool wear) and susceptible to workpiece damage when improper machining parameters are used. It is imperative that the condition of cutting tool being monitored during the machining process of GFRP composites so as to re-compensating the effect of tool wear on the machined components. Until recently, empirical data on tool wear monitoring of this material during end milling process is still limited in existing literature. Thus, this paper presents the development and evaluation of tool condition monitoring technique using measured machining force data and Adaptive Network-Based Fuzzy Inference Systems during end milling of the GFRP composites. The proposed modelling approaches employ two different data partitioning techniques in improving the predictability of machinability response. Results show that superior predictability of tool wear was observed when using feed force data for both data partitioning techniques. In particular, the ANFIS models were able to match the nonlinear relationship of tool wear and feed force highly effective compared to that of the simple power law of regression trend. This was confirmed through two statistical indices, namely r² and root mean square error (RMSE), performed on training as well as checking datasets.     

A data and knowledge-driven cutting parameter adaptive optimization method considering dynamic tool wear

Tool wear prediction is of significance to reduce energy consumption through cutting parameter optimization. However, the current studies ignore the effect of machine aging on the tool wear prediction model, and their cutting parameter optimization methods cannot cope with the dynamic change of tool wear in the machining process. Thus, a reinforcement learning-enabled integrated method of tool wear prediction and cutting parameter optimization is proposed for minimizing energy consumption and production time. Specifically, the multi-source heterogeneous data fusion-based (MHDF) tool wear prediction model considering machine aging is first proposed to obtain the tool wear of the cutting tool. Then, a Markov Decision Process is designed to model the cutting parameter optimization process, which can be utilized to determine the proper cutting parameters adapted to the dynamic change of tool wear. Finally, the proposed method is demonstrated by extensive comparative experiments, and the results show that: 1) The proposed tool wear prediction model eliminates the influence of machine aging on prediction accuracy and has better generalizability for the machining data under different machine aging conditions, and its testing accuracy reaches 96.09%. 2) The proposed optimization method can adapt to the dynamic change of tool wear and further reduce the energy consumption and production time by 6.72% and 8.60% compared to that of not considering tool wear. The computation time of the proposed method is reduced by an average of 71.80%.     

Tool condition classification using Hidden Markov Model based on fractal analysis of machined surface textures

The texture of a machined surface generated by a cutting tool, with geometrically well-defined cutting edges, carries essential information regarding the extent of tool wear. There is a strong relationship between the degree of wear of the cutting tool and the geometry imparted by the tool on to the workpiece surface. The monitoring of a tool’s condition in production environments can easily be accomplished by analyzing the surface texture and how it is altered by a cutting edge experiencing progressive wear and micro-fractures. This paper discusses our work which involves fractal analysis of the texture of surfaces that have been subjected to machining operations. Two characteristics of the texture, high directionality and self-affinity, are dealt with by extracting the fractal features from images of surfaces machined with tools with different levels of tool wear. The Hidden Markov Model is used to classify the various states of tool wear. In this paper, we show that fractal features are closely related to tool condition and HMM-based analysis provides reliable means of tool condition prediction.     

Optimization of multi-task turning operations under minimal tool waste consideration

Most of the literatures on machining economics problems tend to focus on single cutting operations. However, in reality most parts that need to be machined require more than one operation. In addition, machining technology has been developed to the point that a single computer numerical control (CNC) machine is capable of performing multiple operations, even simultaneously, employing multiple spindles and cutting tools. When several operations are performed on a CNC turning machine, various tools are required for the cutting operations. Determining the life of these cutting tools under different machining conditions is an arduous task for the operators. They usually replace the tools based on their experience or according to the specific cutting tool handbook. Frequent tool replacements may result in wasted tools and tool utilization, while infrequent tool replacements may result in poorly machined parts. In this study we propose a mathematical model in which several different turning operations (turning, drilling, and parting) with proper constraints are performed. The issue of tool replacement is taken into account in the proposed cutting model. In addition, an evolutionary strategy (ES)-based optimization approach is developed to optimize the cutting conditions of the multiple turning-related operations while taking into account the minimizing unit cost criteria under the economical tool replacement strategy.     

Adaptive neuro-fuzzy inference system modeling of cryogenically treated AISI M2 HSS turning tool for estimation of flank wear

This study deals with modeling the flank wear of cryogenically treated AISI M2 high speed steel (HSS) tool by means of adaptive neuro-fuzzy inference system (ANFIS) approach. Cryogenic treatment has recently been found to be an innovative technique to improve wear resistance of AISI M2 HSS tools but precise modelling approach which also incorporates the cryogenic soaking temperature to simulate the tool flank wear is still not reported in any open literature. In order to obtain data for developing the ANFIS model, turning of hot rolled annealed steel stock (C-45) by cryogenically treated tools treated at various cryogenic soaking temperatures was performed in steady state conditions while varying the cutting speed and cutting time. The model combined modeling function of fuzzy inference with the learning ability of artificial neural network; and a set of rules has been generated directly from experimental data. It was determined that the predictions usually agreed well with the experimental data with correlation coefficients of 0.994 and mean errors of 2.47%. The proposed model can also be used for estimating tool flank wear on-line but the accuracy of the model depends upon the proper training and selection of data points.     

Cutting tool wear estimation for turning

The experimental investigation on cutting tool wear and a model for tool wear estimation is reported in this paper. The changes in the values of cutting forces, vibrations and acoustic emissions with cutting tool wear are recoded and analyzed. On the basis of experimental results a model is developed for tool wear estimation in turning operations using Adaptive Neuro fuzzy Inference system (ANFIS). Acoustic emission (Ring down count), vibrations (acceleration) and cutting forces along with time have been used to formulate model. This model is capable of estimating the wear rate of the cutting tool. The wear estimation results obtained by the model are compared with the practical results and are presented. The model performed quite satisfactory results with the actual and predicted tool wear values. The model can also be used for estimating tool wear on-line but the accuracy of the model depends upon the proper training and section of data points.     

Calibration-based tool condition monitoring for repetitive machining operations

Reliable tool condition monitoring (TCM) system is essential for any machining process in mass production to control the part quality as well as reduce the machine tool downtime and maintenance costs. However, while various research studies have proposed their TCM systems, the complexity in setups with advanced decision-making algorithms and specificity in application to limited cutting conditions continue to complicate the implementation of these systems into practical scenarios. This study develops a very simple and flexible TCM system for repetitive machining operations. The proposed monitoring approach reduces the complexity of monitoring model by considering the important characteristic of repeatability in process which has been commonly found in the mass production scenario and implements the calibration procedure to improve the flexibility of the model application to actual machining processes with complex toolpath designs and variable cutting conditions. The selected cutting tools with specific tool conditions are used in the calibration phase to generate reference signals. In actual repetitive production, the collected signal generated by the cutting tool in each operation is compared with reference signals to identify the most similar condition of the reference tool through the proposed similarity analysis. To validate the performance, the current study demonstrates the application of proposed monitoring approach to monitor the tool wear in repetitive milling operations with complex toolpath, and the predicted tool wear progression is found to be in good agreement with experimental measurements during the machining of multiple parts over the entire tool life.     

Tool wear monitoring using neuro-fuzzy techniques: a comparative study in a turning process

Tool wear detection is a key issue for tool condition monitoring. The maximization of useful tool life is frequently related with the optimization of machining processes. This paper presents two model-based approaches for tool wear monitoring on the basis of neuro-fuzzy techniques. The use of a neuro-fuzzy hybridization to design a tool wear monitoring system is aiming at exploiting the synergy of neural networks and fuzzy logic, by combining human reasoning with learning and connectionist structure. The turning process that is a well-known machining process is selected for this case study. A four-input (i.e., time, cutting forces, vibrations and acoustic emissions signals) single-output (tool wear rate) model is designed and implemented on the basis of three neuro-fuzzy approaches (inductive, transductive and evolving neuro-fuzzy systems). The tool wear model is then used for monitoring the turning process. The comparative study demonstrates that the transductive neuro-fuzzy model provides better error-based performance indices for detecting tool wear than the inductive neuro-fuzzy model and than the evolving neuro-fuzzy model.     

Machine tool condition monitoring using workpiece surface texture analysis

Tool wear affects the surface roughness dramatically. There is a very close correspondence between the geometrical features imposed on the tool by wear and micro-fracture and the geometry imparted by the tool on to the workpiece surface. Since a machined surface is the negative replica of the shape of the cutting tool, and reflects the volumetric changes in cutting-edge shape, it is more suitable to analyze the machined surface than look at a certain portion of the cutting tool. This paper discusses our work that analyzes images of workpiece surfaces that have been subjected to machining operations and investigates the correlation between tool wear and quantities characterizing machined surfaces. Our results clearly indicate that tool condition monitoring (the distinction between a sharp, semi-dull, or a dull tool) can be successfully accomplished by analyzing surface image data. Received: 9 June 1998 / Accepted: 6 October 1999     

Condition monitoring of CNC machining using adaptive control

In this work, an adaptive control constraint system has been developed for computer numerical control (CNC) turning based on the feedback control and adaptive control/self-tuning control. In an adaptive controlled system, the signals from the online measurement have to be processed and fed back to the machine tool controller to adjust the cutting parameters so that the machining can be stopped once a certain threshold is crossed. The main focus of the present work is to develop a reliable adaptive control system, and the objective of the control system is to control the cutting parameters and maintain the displacement and tool flank wear under constraint valves for a particular workpiece and tool combination as per ISO standard. Using Matlab Simulink, the digital adaption of the cutting parameters for experiment has confirmed the efficiency of the adaptively controlled condition monitoring system, which is reflected in different machining processes at varying machining conditions. This work describes the state of the art of the adaptive control constraint (ACC) machining systems for turning. AISI4140 steel of 150 BHN hardness is used as the workpiece material, and carbide inserts are used as cutting tool material throughout the experiment. With the developed approach, it is possible to predict the tool condition pretty accurately, if the feed and surface roughness are measured at identical conditions. As part of the present research work, the relationship between displacement due to vibration, cutting force, flank wear, and surface roughness has been examined.     

A sensor fusion and support vector machine based approach for recognition of complex machining conditions

During the machining process of thin-walled parts, machine tool wear and work-piece deformation always co-exist, which make the recognition of machining conditions very difficult. Existing machining condition monitoring approaches usually consider only one single condition, i.e., either tool wear or work-piece deformation. In order to close this gap, a machining condition recognition approach based on multi-sensor fusion and support vector machine (SVM) is proposed. A dynamometer sensor and an acceleration sensor are used to collect cutting force signals and vibration signals respectively. Wavelet decomposition is utilized as a signal processing method for the extraction of signal characteristics including means and variances of a certain degree of the decomposed signals. SVM is used as a condition recognition method by using the means and variances of signals as well as cutting parameters as the input vector. Information fusion theory at the feature level is adopted to assist the machining condition recognition. Experiments are designed to demonstrate and validate the feasibility of the proposed approach. A condition recognition accuracy of about 90 % has been achieved during the experiments.     

Tool wear assessment based on type-2 fuzzy uncertainty estimation on acoustic emission

In modern manufacturing industry, developing automated tool condition monitoring system become more and more import in order to transform manufacturing systems from manually operated production machines to highly automated machining centres. This paper presents a nouvelle cutting tool wear assessment in high precision turning process using type-2 fuzzy uncertainty estimation on acoustic Emission. Without understanding the exact physics of the machining process, type-2 fuzzy logic system identifies acoustic emission signal during the process and its interval set of output assesses the uncertainty information in the signal. The experimental study shows that the development trend of uncertainty in acoustic emission signal corresponds to that of cutting tool wear. The estimation of uncertainties can be used for proving the conformance with specifications for products or auto-controlling of machine system, which has great meaning for continuously improvement in product quality, reliability and manufacturing efficiency in machining industry.     

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.     

Numerical analysis of the tool wear effect in the machining induced residual stresses

Machining is a dynamic process involving coupled phenomena: high strain and strain rate and high temperature. Prediction of machining induced residual stresses is an interesting objective at the manufacturing processes modelling field. Tool wear results in a change of tool geometry affecting thermo-mechanical phenomena and thus has a significant effect on residual stresses. The experimental study of the tool wear influence in residual stresses is difficult due to the need of controlling wear evolution during cutting. Also the involved phenomena make the analysis extremely difficult. On the other hand, Finite Element Analysis (FEA) is a powerful tool used to simulate cutting processes, allowing the analysis of different parameters influent on machining induced residual stresses.The aim of this work is to develop and to validate a numerical model to analyse the tool wear effect in machining induced residual stresses. Main advantages of the model presented in this work are, reduced mesh distortion, the possibility to simulate long length machined surface and time-efficiency. The model was validated with experimental tests carried out with controlled worn geometry generated by electro-discharge machining (EDM). The model was applied to predict machining induced residual stresses in AISI 316 L and reasonable agreement with experimental results were found.     

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.     

Artificial intelligence for automatic prediction of required surface roughness by monitoring wear on face mill teeth

Nowadays, face milling is one of the most widely used machining processes for the generation of flat surfaces. Following international standards, the quality of a machined surface is measured in terms of surface roughness, Ra, a parameter that will decrease with increased tool wear. So, cutting inserts of the milling tool have to be changed before a given surface quality threshold is exceeded. The use of artificial intelligence methods is suggested in this paper for real-time prediction of surface roughness deviations, depending on the main drive power, and taking tool wear, \(V_{B}\) into account. This method ensures comprehensive use of the potential of modern CNC machines that are able to monitor the main drive power, N, in real-time. It can likewise estimate the three parameters -maximum tool wear, machining time, and cutting power- that are required to generate a given surface roughness, thereby making the most efficient use of the cutting tool. A series of artificial intelligence methods are tested: random forest (RF), standard Multilayer perceptrons (MLP), Regression Trees, and radial-based functions. Random forest was shown to have the highest model accuracy, followed by regression trees, displaying higher accuracy than the standard MLP and the radial-basis function. Moreover, RF techniques are easily tuned and generate visual information for direct use by the process engineer, such as the linear relationships between process parameters and roughness, and thresholds for avoiding rapid tool wear. All of this information can be directly extracted from the tree structure or by drawing 3D charts plotting two process inputs and the predicted roughness depending on workshop requirements.     

Multilevel classification of milling tool wear with confidence estimation

An important problem during industrial machining operations is the detection and classification of tool wear. Past research in this area has demonstrated the effectiveness of various feature sets and binary classifiers. Here, the goal is to develop a classifier which makes use of the dynamic characteristics of tool wear in a metal milling application and which replaces the standard binary classification result with two outputs: a prediction of the wear level (quantized) and a gradient measure that is the posterior probability (or confidence) that the tool is worn given the observed feature sequence. The classifier tracks the dynamics of sensor data within a single cutting pass as well as the evolution of wear from sharp to dull. Different alternatives to parameter estimation with sparsely-labeled training data are proposed and evaluated. We achieve high accuracy across changing cutting conditions, even with a limited feature set drawn from a single sensor.