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.     

基于随机模糊神经网络的刀具磨损量软测量技术

刀具磨损检测对于提高加工过程的自动化、高精度化、智能化具有重要意义．本文通 过检测电流信号基于随机模糊神经网络建立了刀具磨损量的软测量模型．该模型的创新之处 在于利用切削参数实时地调整网络的部分参数,从而可以减小切削参数与电流信号之间关系 对于刀具磨损估计的影响并且使得模型具有动态性、实时性．实验验证表明该方法是正确而 有效的．     

Online tool wear prediction system in the turning process using an adaptive neuro-fuzzy inference system

Tool wear is a detrimental factor that affects the quality and tolerance of machined parts. Having an accurate prediction of tool wear is important for machining industries to maintain the machined surface quality and can consequently reduce inspection costs and increase productivity. Online and real-time tool wear prediction is possible due to developments in sensor technology. Recently, various sensors and methods have been proposed for the development of tool wear monitoring systems. In this study, an online tool wear monitoring system was proposed using a strain gauge-type sensor due to its simplicity and low cost. A model, based on the adaptive network-based fuzzy inference system (ANFIS), and a new statistical signal analysis method, the I-kaz method, were used to predict tool wear during a turning process. In order to develop the ANFIS model, the cutting speed, depth of cut, feed rate and I-kaz coefficient from the signals of each turning process were taken as inputs, and the flank wear value for the cutting edge was an output of the model. It was found that the prediction usually accurate if the correlation of coefficients and the average errors were in the range of 0.989–0.995 and 2.30–5.08% respectively for the developed model. The proposed model is efficient and low-cost which can be used in the machining industry for online prediction of the cutting tool wear progression, but the accuracy of the model depends upon the training and testing data.     

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.     

Feature-filtered fuzzy clustering for condition monitoring of tool wear

Condition monitoring is of vital importance in order to assess the state of tool wear in unattended manufacturing. Various methods have been attempted, and it is considered that fuzzy clustering techniques may provide a realistic solution to the classification of tool wear states. Unlike fuzzy clustering methods used previously, which postulate cutting condition parameters as constants and define clustering centres subjectively, this paper presents a fuzzy clustering method based on filtered features for the monitoring of tool wear under different cutting conditions. The method uses partial factorial experimental design and regression analysis for the determination of coefficients of a filter, then calculates clustering centres for filtering the effect of various cutting conditions, and finally uses a developed mathematical model of membership functions for fuzzy classification. The validity and reliability of the method are experimentally illustrated using a CNC machining centre for milling.     

On-line tool condition monitoring system with wavelet fuzzy neural network

In manufacturing systems such as flexible manufacturing systems (FMS), one of the most important issues is accurate detection of the tool conditions under given cutting conditions. An investigation is presented of a tool condition monitoring system (TCMS), which consists of a wavelet transform preprocessor for generating features from acoustic emission (AE) signals, followed by a high speed neural network with fuzzy inference for associating the preprocessor outputs with the appropriate decisions. A wavelet transform can decompose AE signals into different frequency bands in the time domain. The root mean square (RMS) values extracted from the decomposed signal for each frequency band were used as the monitoring feature. A fuzzy neural network (FNN) is proposed to describe the relationship between the tool conditions and the monitoring features; this requires less computation than a back propagation neural network (BPNN). The experimental results indicate the monitoring features have a low sensitivity to changes of the cutting conditions and FNN has a high monitoring success rate in a wide range of cutting conditions; TCMS with a wavelet fuzzy neural network is feasible.     

An intelligent hybrid approach for industrial quality control combining neural networks, fuzzy logic and fractal theory

The application of type-2 fuzzy logic to the problem of automated quality control in sound speaker manufacturing is presented in this paper. Traditional quality control has been done by manually checking the quality of sound after production. This manual checking of the speakers is time consuming and occasionally was the cause of error in quality evaluation. For this reason, by applying type-2 fuzzy logic, an intelligent system for automated quality control in sound speaker manufacturing is developed. The intelligent system has a type-2 fuzzy rule base containing the knowledge of human experts in quality control. The parameters of the fuzzy system are tuned by applying neural networks using, as training data, a real time series of measured sounds produced by good sound speakers. The fractal dimension is used as a measure of the complexity of the sound signal.     

加工过程的模糊自适应PID控制

经典的加工过程模型随切削深度、主轴转速、加工材料、刀具形状和磨损程度不同而不同,因而具有时变性。实际加工过程要比理论上推导出的模型复杂得多,是一种具有非线性、时变性和影响因素不确定的复杂系统,甚至难以用合适的数学模型来表示。结合PID和模糊控制两者的优点,建立一种加工过程的模糊自适应PID的控制方法。对模糊自适应PID控制算法进行了理论分析,基于Matlab建立了铣削加工过程的仿真模型。仿真结果表明,运用模糊自适应PID控制方法,系统的调节时间缩短,响应速度加快,抗干扰能力和适应参数变化的能力要优于增益自适应的PID控制。     

On-line robust identification of tool-wear via multi-sensor neural-network fusion

Real-time identification and monitoring of tool-wear in shop-floor environments is essential for the optimization of machining processes and the implementation of automated manufacturing systems. This paper analyzes the signals from an acoustic emission sensor and a power sensor during machining processes, and extracts a set of feature parameters that characterize the tool-wear conditions. In order to realize real-time and robust tool-wear monitoring for different cutting conditions, a sensor-integration strategy that combines the information obtained from multiple sensors (acoustic emission sensor and power sensor) with machining parameters is proposed. A neural network based on an improved backpropagation algorithm is developed, and a prototype scheme for the real-time identification of tool-wear is implemented. Experiments under different conditions have proved that a higher rate of tool-wear identification can be achieved by using the sensor integration model with a neural network. The results also indicate that neural networks provide a very effective method of implementing sensor integration for the on-line monitoring of tool abnormalities.     

一种新型高灵敏度双叠片式流体声发射传感器的研制

研制高灵敏度、安装使用方便、抗干扰能力强的传感器是实现刀具磨损在线监测的关键.参考空气声学中常用的压差式微音器的典型结构,考虑自动化加工中使用的要求,研制成功可用于刀具磨损状态监测的非接触高灵敏度双叠片式流体声发射传感器.对研制的流体声发射传感器性能进行了实验分析,结果表明传感器对刀具磨损产生的声发射信号具有较高的灵敏度.     

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.     

In-process tool condition forecasting based on a deep learning method

It is widely acknowledged that machining precision and surface integrity are greatly affected by cutting tool conditions. In order to enable early cutting tool replacement and proactive actions, tool wear conditions should be estimated in advance and updated in real-time. In this work, an approach to in-process tool condition forecasting is proposed based on a deep learning method. A long short-term memory network is designed to forecast multiple flank wear values based on historical data. A residual convolutional neural network is built to enable in-process tool condition monitoring, using raw signals acquired during the machining process. The integration of them enables in-process tool condition forecasting. Median-based correction and mean-based correction are adopted to improve the accuracy. IEEE PHM 2010 challenge data has been used to illustrate and validate this approach. Experimental study and quantitative comparisons showed that future flank wear values could be precisely forecasted during the machining process. The proposed approach contributes to prompt and reliable cutting tool condition forecasting, which will support the decision-making about cutting tool replacement in data-driven smart manufacturing.     

Research on multi-signal milling tool wear prediction method based on GAF-ResNext

A key aspect impacting the quality and efficiency of machining is the degree of tool wear. If the tool failure is not discovered in time, the quality of workpiece processing decreases, and even the machine tool itself may be harmed. To increase machining quality, efficiency and facilitate the intelligent advancement of the manufacturing industry, tool wear prediction is crucial. This research offers a multi-signal tool wear prediction method based on the Gramian angular field (GAF) and depth aggregation residual transform neural network (ResNext), enabling fast and accurate tool wear prediction. Specifically, the required one-dimensional signal is obtained through preprocessing including intercepting, splicing and wavelet threshold denoising of the force and vibration signals, and GAF is used to encode the obtained one-dimensional signal to generate a (224 × 224) data matrix. ResNext automatically extracts the features of the data matrix, establish the relationship between features and tool wear, and creates a tool wear prediction model based on GAF-ResNext. The ability of this method to predict tool wear has been trained and tested by milling experimental data. The experimental findings demonstrate the real-time, accuracy, dependability and universality of this method. This method has a better effect when compared to other research methods. The study's findings can boost machining productivity and offer technical support for intelligent tool wear early warning and intelligent manufacturing.     

Basic computational tools and mechanical hardware for torque-based diagnostic of machining operations

In the industry, only rotary dynamometers can be used for monitoring when multiple spindles are used in machining operations. The current commercial rotary dynamometers are bulky and expensive for most machining centers. The basic hardware and computational tools proposed are for a smaller, more cost effective Torque-based Machining Monitor (TbMM). The objective of the TbMM concept is to estimate the remaining tool life, detect chatter from the torque signal inside the proposed device, and communicate with the central computer only when problems arise. The remaining tool life estimation and chatter detection algorithms of the TbMM were developed by analyzing the experimental data collected by a commercial rotary dynamometer. The mechanical hardware of the TbMM was designed to generate voltage proportional to the cutting torque using a piezoelectric composite element. The remaining tool life was estimated from the standard deviation (or variance) of the torque signal. Teager-Kaiser algorithm (TKA) based procedure detected the chatter based on the frequency estimations only from four samples at a time. The accuracy and characteristics of the signal of the mechanical component of the TbMM were found satisfactory in the estimation of machining problems such as wear and chatter. The TbMM is a good choice particularly when multiple spindles work simultaneously on the same workpiece.     

Tool wear state recognition based on linear chain conditional random field model

Tool condition monitoring (TCM) system is paramount for guaranteeing the quality of workpiece and improving the efficiency of the machining process. To overcome the shortcomings of Hidden Markov Model (HMM) and improve the accuracy of tool wear recognition, a linear chain conditional random field (CRF) model is presented. As a global conditional probability model, the main characteristic of this method is that the estimation of the model parameters depends not only on the current feature vectors but also on the context information in the training data. Therefore, it can depict the interrelationship between the feature vectors and the tool wear states accurately. To test the effectiveness of the proposed method, acoustic emission data are collected under four kinds of tool wear state and seven statistical features are selected to realize the tool wear classification by using CRF and hidden Markov model (HMM) based pattern recognition method respectively. Moreover, k-fold cross validation method is utilized to estimate the generation error accurately. The analysis and comparison under different folds schemes show that the CRF model is more accurate for the classification of the tool wear state. Moreover, the stability and the training speed of the CRF classifier outperform the HMM model. This method casts some new lights on the tool wear monitoring especially in the real industrial environment.     

TSK fuzzy modeling for tool wear condition in turning processes: An experimental study

This paper presents an experimental study for turning process in machining by using Takagi-Sugeno-Kang (TSK) fuzzy modeling to accomplish the integration of multi-sensor information and tool wear information. It generates fuzzy rules directly from the input-output data acquired from sensors, and provides high accuracy and high reliability of the tool wear prediction over a wide range of cutting conditions. The experimental results show its effectiveness and satisfactory comparisons relative to other artificial intelligence methods.     

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.     

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.     

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.     

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.