Design of neural network-based estimator for tool wear modeling in hard turning |
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Authors: | Xiaoyu Wang Wen Wang Yong Huang Nhan Nguyen Kalmanje Krishnakumar |
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Affiliation: | (1) Department of Mechanical Engineering, Clemson University, Clemson, SC 29634-0921, USA;(2) College of Mechanical and Energy Engineering, Zhejiang University, Hangzhou, 310027, P.R. China;(3) Intelligent Systems Division, NASA Ames Research Center, Moffett Field, CA 94035, USA |
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Abstract: | 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. |
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Keywords: | Tool wear Hard turning Neural network Extended Kalman filter Connectivity optimization |
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