Tool Wear Condition Monitoring Research Articles

Research on tool wear condition monitoring based on deep transfer learning and residual network

To address the issues of sample scarcity and insufficient recognition accuracy in existing deep learning models for tool wear monitoring, this study developed a milling tool wear monitoring model that combines transfer learning (TL) and deep residual networks (ResNet). The model uses continuous wavelet transform to convert vibration signals into time-frequency maps, which are then fed into the network model for analysis. ResNet50 was selected as the base feature extraction model, and transfer learning techniques were employed to update the classification layer’s weights, enabling tool wear detection. The model based on ResNet-TL achieved a detection accuracy of 94%, significantly exceeding the threshold for intelligent tool wear recognition. This accomplishment markedly improves the precision and stability of tool wear state monitoring, providing more reliable technical support for tool management in manufacturing processes. Additionally, the method demonstrated superiority in addressing the small sample problem, paving the way for future research in tool wear monitoring. By integrating advanced deep learning techniques with transfer learning, the model not only enhances detection capabilities but also improves adaptability and robustness in practical industrial applications.

Advances in Research on Tool Wear Online Monitoring Method

Background: With the continued advancement of industrial internet technology, mechanical manufacturing is increasingly developing towards automation and intelligence. As a result, monitoring the manufacturing process has become an essential requirement for intelligent manufacturing. As one of the fundamental components of cutting processes, tools are inevitably subject to wear and damage during use. Therefore, tool wear monitoring plays a crucial role in modern manufacturing. Introduction: With the development of the manufacturing industry, the requirement for automation manufacturing is higher and higher. In the process of automatic processing, unmanned processing and adaptive processing, it is not only required to be able to know the accurate wear state of the tool in the process real-time but also required to change the milling parameters according to the wear state of the tool, in order to optimize the productivity and processing quality. The tool monitoring system can effectively reduce the operating cost of workshop production and improve the reliability of intelligent workshop and flexible production lines. Method: This article summarizes commonly used online monitoring methods mentioned by articles and patents, such as cutting force, vibration, acoustic emission, temperature, current, and power signals. Each monitoring method is analyzed in terms of its principles, advantages and disadvantages, signal acquisition equipment, and research status. The article also identifies current issues and future development directions. Results: As modern manufacturing technology continues to develop rapidly, unmanned factories have become a significant feature of the manufacturing industry. Consequently, the need for tool wear condition monitoring technology is becoming increasingly urgent. Although tool condition monitoring technology has made significant progress over the past twenty years and has been applied in actual production, several issues need to be addressed to make tool wear condition monitoring systems mo. Conclusion: This serves as a reference for theoretical research and application of online monitoring of tool wear in intelligent manufacturing systems.

Multi-sensor signal fusion for tool wear condition monitoring using denoising transformer auto-encoder Resnet

Multi-sensor signal fusion is commonly used in associate with the artificial intelligence model to monitor tool wears. However, AI models equipped with limited multi-sensor training samples still exist problems: 1) The limitation of training samples may cause the AI model failure due to the intrinsic wear features contaminated by heavy noises. 2) The selection of multi-sensor signals as training samples is a difficult task for the negative impact on the recognition accuracy using inappropriate sensor features. Therefore, this paper proposes a denoise transformer Auto-Encoder (DTAE) as pre-processor for the tool condition monitoring (TCM) classifiers. The reconstruction task of the DTAE allows the model to pay more attention to the intrinsic wear features and the appropriate selection of them from the multi-sensor signals during feature extraction. Moreover, the loss function for DTAE ResNet is formed by summing the reconstruction loss from DTAE with the classification loss from ResNet. Compared DTAE ResNet to stacked sparse auto-encoder network, deep stacked auto-encoder network, ResNet-18, VGG-16, and LSTM, experiments demonstrated that the present method would attain the highest classification accuracies for tool wear suitable for TCM. And a comparative experiment was conducted to verify the effectiveness of the DTAE preprocessor in improving the anti-noise performance of the classifier.

An end-to-end deep learning approach for tool wear condition monitoring

An end-to-end deep learning approach for tool wear condition monitoring

In-situ tool wear condition monitoring during the end milling process based on dynamic mode and abnormal evaluation

Rapid tool wear conditions during the manufacturing process are crucial for the enhancement of product quality. As an extension of our recent works, in this research, a generic in-situ tool wear condition monitoring during the end milling process based on dynamic mode and abnormal evaluation is proposed. With the engagement of dynamic mode decomposition, the real-time response of the sensing physical quantity during the end milling process can be predicted. Besides, by constructing the graph structure of the time series and calculating the difference between the predicted signal and the real-time signal, the anomaly can be acquired. Meanwhile, the tool wear state during the end milling process can be successfully evaluated. The proposed method is validated in milling tool wear experiments and received positive results (the mean relative error is recorded as 0.0507). The research, therefore, paves a new way to realize the in-situ tool wear condition monitoring.

Research on tool wear state identification method driven by multi-source information fusion and multi-dimension attention mechanism

Cutting tool wear condition monitoring technology is the key technology of advanced manufacturing system and a crucial component of machining. The stage of the tool wear has a direct impact on performance of the workpiece and efficacy of machine tool. However, the duplication and lack of wear information and the fuzzy area of the tool wear transition stage are the key factors contributing to the incorrect estimation of the tool wear state when extracting cutting tool wear feature information. As a consequence, this study presents a data fusion from several sources-based intelligent tool wear state detection technique. The fusion of data from several sources can effectively realize the complementarity of machining information. This provides the model with more comprehensive identification data. The mapping between wear state and wear characteristics is precisely established. To address these issues, the attention mechanism of channel and spatial latitude is integrated into the feature extraction. The model that was constructed in the present investigation has a comprehensive identification accuracy of 0.982. The F1 score of initial, normal and severe wear stage of tool wear are 0.977, 0.968 and 0.993, which are better than other models. Experiments show that the identification method proposed in this study may provide accurate tool wear condition identification based on machining process data, allowing for more flexible and precise cutting tool change decisions in machining.

Cross-domain tool wear condition monitoring via residual attention hybrid adaptation network

Intelligent models for tool wear condition monitoring (TWCM) have been extensively researched. However, in industrial scenarios, limited acquired monitoring signals and variations of machining parameters lead to insufficient training samples and data distribution shifts for the models. To address the issues, this research presents a novel residual attention hybrid adaptation network (RAHAN) model based on a residual attention network (ResAttNet) and a hybrid adaptation strategy. In the RAHAN model, by integrating a channel attention mechanism and deep residual modules, ResAttNet is designed as a feature extractor to acquire features from monitoring signals for tool wear conditions. Embedding subdomain adaptation into a condition recognizer while establishing separate adversarial learning in a domain obfuscator, the hybrid adaptation strategy is developed to eliminate global distribution shifts and align local distributions of each tool wear phase simultaneously. Six migration tasks under a laboratory and two factory machining platforms were conducted to evaluate the effectiveness of the RAHAN model. Compared with a baseline model, four ablation models, and six state-of-the-art transfer learning models, the RAHAN model achieved the highest average accuracy of 92.70% on six migration tasks. Furthermore, the RAHAN model shows clearer feature representations of each tool wear condition than other compared models. The comparative results demonstrate that the RAHAN model has superior transferability and therefore can be considered as a good potential solution to support cross-domain TWCM under different machining processes.

A tool wear condition monitoring method for non-specific sensing signals

Real-time and accurate monitoring of tool wear conditions is crucial to achieving double optimization of production cost and product quality. However, the differences in the characteristics of different signals limit the ability of the monitoring model to generalize between sensing channels, which becomes an important factor limiting the promotion of the model. To solve this problem, an improved parallel residual network based on single-channel and non-specific sensing signals is proposed in this paper. The limitation of the single-channel signal with little information and poor anti-interference ability is overcome by adaptively extracting the multi-scale spatial features of the sensing signal. Hybrid dilated convolution is introduced to expand the receptive field, and then the long historical domain information is obtained. At the same time, the information dependence between layers is enhanced by introducing skip connections. These two designs ensure the perceptual generalization ability of the model. Considering the tool replacement time and the imbalance classification of labels, a comprehensive evaluation method is proposed for model performance evaluation. In addition, the variation law of tool wear in the milling process of Ti-6Al-4V thin-walled parts is investigated. Finally, the validity and transferability of the model are verified by two milling datasets with different cutting conditions. On the basis of ensuring the perceptual generalization ability of the model, the differences in model performance based on acceleration and cutting force signals are controlled within 4.5 % and 1 %, respectively, and the overall average recognition performance is 96.3 % and 92.5 %, respectively. This study provides a feasible solution for intelligent tool replacement in the actual machining environment.

Tool wear condition monitoring method based on relevance vector machine

Tool wear condition monitoring method based on relevance vector machine

Synthetic Minority Oversampling Enhanced FEM for Tool Wear Condition Monitoring

Recent advances in artificial intelligence (AI) technology have led to increasing interest in the development of AI-based tool wear condition monitoring methods, heavily relying on large training samples. However, the high cost of tool wear experiment and the uncertainty of tool wear change in the machining process lead to the problems of sample missing and insufficiency in the model training stage, which seriously affects the identification accuracy of many AI models. In this paper, a novel identification method based on finite-element modeling (FEM) and the synthetic minority oversampling technique (SMOTE) is proposed to overcome the problem of sample missing and sample insufficiency. Firstly, a few tool wear monitoring experiments are carried out to obtain experimental samples with low cost. Then, a FEM model based on the Johnson–Cook constitutive model was established and verified according to the experimental samples. Based on the verified FEM model, the simulated missing sample in the experiments can be supplemented to compose a complete training set. Finally, the SMOTE is employed to expand the sample size to construct a perfect training set to train the SVM classification model. End milling tool wear monitoring experiments demonstrate that the proposed FEM-SMOTE method can obtain 98.7% identification accuracy, which is 30% higher than that based on experimental samples. The proposed method provides an effective approach for tool wear condition monitoring with low experimental cost.

A novel online tool condition monitoring method for milling titanium alloy with consideration of tool wear law

Due to issues such as limited variability in monitoring data across different tool wear conditions and interference during the machining process, data-driven monitoring models are susceptible to misclassification. Therefore, this paper proposes a pioneering approach that takes into account the tool wear law and the characteristic distribution of tool wear monitoring data. Specifically, the paper proposes an automatic feature extraction and tool condition monitoring method based on Siamese Long Short-term Memory Networks (SLSTMs) to transform the original data distribution, enhance the differentiation of different tool wear condition monitoring data, and achieve accurate prediction of tool wear condition. Additionally, a hybrid data and mechanism-driven tool wear monitoring method is proposed that takes advantage of the fact that tool wear is continuous and irreversible to enable reliable adjustment of the monitoring results of the data-driven model without human intervention. The study conducted milling experiments on a three-axis vertical machining center, using TA2 titanium alloy as the workpiece material. Vibration signals from the spindle in three directions were collected as input to the network, with tool wear state labeled as “0″ or ”1″ as the output. Classical machine learning algorithms such as Decision Trees, K-Nearest Neighbors (KNN) and Support Vector Machines (SVM), as well as classical deep learning algorithms such as Convolutional Neural Networks (CNN), Sparse Stacked Autoencoders (SSAE) and Long Short-Term Memory Neural Networks (LSTM), were used to construct and compare feature extraction and state monitoring models. The proposed model based on Siamese Long Short-Term Memory Neural Networks (SLSTMs) achieved testing average accuracy of 98.2% (σ2 = 0.44), outperforming typical deep learning algorithms such as CNN, LSTM and SSAE as well as traditional machine learning algorithms such as Decision Trees, KNN and SVM in terms of accuracy and robustness. Moreover, the proposed data and mechanism hybrid-driven tool wear monitoring method can effectively improve the monitoring accuracy and robustness of data-driven models such as CNN and SSAE. The monitoring accuracy of CNN and SSAE increased from 95.9% to 97.6% and 91.0% to 94.3%, respectively.

Tool Wear Condition Monitoring Method Based on Deep Learning with Force Signals.

Tool wear condition monitoring is an important component of mechanical processing automation, and accurately identifying the wear status of tools can improve processing quality and production efficiency. This paper studied a new deep learning model, to identify the wear status of tools. The force signal was transformed into a two-dimensional image using continuous wavelet transform (CWT), short-time Fourier transform (STFT), and Gramian angular summation field (GASF) methods. The generated images were then fed into the proposed convolutional neural network (CNN) model for further analysis. The calculation results show that the accuracy of tool wear state recognition proposed in this paper was above 90%, which was higher than the accuracy of AlexNet, ResNet, and other models. The accuracy of the images generated using the CWT method and identified with the CNN model was the highest, which is attributed to the fact that the CWT method can extract local features of an image and is less affected by noise. Comparing the precision and recall values of the model, it was verified that the image obtained by the CWT method had the highest accuracy in identifying tool wear state. These results demonstrate the potential advantages of using a force signal transformed into a two-dimensional image for tool wear state recognition and of applying CNN models in this area. They also indicate the wide application prospects of this method in industrial production.

Tool wear condition monitoring across machining processes based on feature transfer by deep adversarial domain confusion network

Tool wear condition monitoring across machining processes based on feature transfer by deep adversarial domain confusion network

Development of tool wear condition on-line monitoring method for impeller milling based on new data processing approach and DAE-BP-ANN-integrated modeling

Tool wear condition monitoring plays an important role in the maintaining machining accuracy and machining efficiency of complex surface parts. In this study, a new on-line tool wear monitoring method based on a self-developed data processing approach for the impeller milling was proposed. To achieve that, a new tool wear experimental platform was first built to collect both the spindle current signal and thermal deformation data in entire life cycle of cutter. Based on collected data, features of the time domain, frequency domain and time-frequency domain were extracted indiscriminately, and a 38 × 156 feature-sample set was subsequently established. To further reduce the dimensions of this feature-sample set and rise its characterization capability, the feature set was further processed using the sensitivity analysis and deep auto-encoder algorithm. Finally, 12 synthesized features were filtered out and then used to build the mapping model of signal synthesized features to different tool wear conditions by adopting the structural artificial neural network (ANN) integrated with back propagation (BP) algorithm. To verify the reliability of the proposed BP-ANN-integrated tool wear condition monitoring model, another comparison analysis of different data processing approaches was conducted. The comparison results showed that the proposed method for tool wear condition online monitoring had reliable performance and the recognition accuracy was 88.9%.

Tool wear condition monitoring based on multi-sensor integration and deep residual convolution network

In order to guarantee machining quality and production efficiency and as well as to reduce downtime and cost, it is essential to receive information about the cutting tool condition and change it in time if necessary. To this end, tool condition monitoring systems are of great significance. Based on the data fusion technology of multi-sensor integration and the learning ability of deep residual network, a tool wear monitoring system is proposed in this paper. For data acquisition, multiple sensors are used to collect vibration, noise and acoustic emission signals in the machining process. For signal processing, the data fusion method of angular summation of matrices is used, so that the multi-source data are fused into two-dimensional pictures. Then, the feature extraction module of the proposed system uses the pictures as input and takes advantage of the deep residual convolutional network in extracting the deep features from the pictures, and finally the identification module completes the recognition of the tool wear type. To verify its feasibility, a testing bed is built on a CNC milling machine, and multi-sensor data are collected during the machining process of a simple workpiece with one of the two selected cutting tools each time. The proposed system is trained using the collected data and then is used to monitor the wear condition of a new cutting tool by collecting real-time data under similar condition. The results show that the accuracy of wear state recognition is as high as 90%, which verifies the feasibility of the proposed tool wear monitoring system.

Tool wear condition monitoring method of five-axis machining center based on PSO-CNN

The effective monitoring of tool wear status in the milling process of a five-axis machining center is important for improving product quality and efficiency, so this paper proposes a CNN convolutional neural network model based on the optimization of PSO algorithm to monitor the tool wear status. Firstly, the cutting vibration signals and spindle current signals during the milling process of the five-axis machining center are collected using sensor technology, and the features related to the tool wear status are extracted in the time domain, frequency domain and time-frequency domain to form a feature sample matrix; secondly, the tool wear values corresponding to the above features are measured using an electron microscope and classified into three types: slight wear, normal wear and sharp wear to construct a target Finally, the tool wear sample data set is constructed by using multi-source information fusion technology and input to PSO-CNN model to complete the prediction of tool wear status. The results show that the proposed method can effectively predict the tool wear state with an accuracy of 98.27%; and compared with BP model, CNN model and SVM model, the accuracy indexes are improved by 9.48%, 3.44% and 1.72% respectively, which indicates that the PSO-CNN model proposed in this paper has obvious advantages in the field of tool wear state identification.

A Novel Multivariate Cutting Force-Based Tool Wear Monitoring Method Using One-Dimensional Convolutional Neural Network.

Tool wear condition monitoring during the machining process is one of the most important considerations in precision manufacturing. Cutting force is one of the signals that has been widely used for tool wear condition monitoring, which contains the dynamical information of tool wear conditions. This paper proposes a novel multivariate cutting force-based tool wear monitoring method using one-dimensional convolutional neural network (1D CNN). Firstly, multivariate variational mode decomposition (MVMD) is used to process the multivariate cutting force signals. The multivariate band-limited intrinsic mode functions (BLIMFs) are obtained, which contain a large number of nonlinear and nonstationary tool wear characteristics. Afterwards, the proposed modified multiscale permutation entropy (MMPE) is used to measure the complexity of multivariate BLIMFs. The entropy values on multiple scales are calculated as condition indicators in tool wear condition monitoring. Finally, the one-dimensional feature vectors are constructed and employed as the input of 1D CNN to achieve accurate and stable tool wear condition monitoring. The results of the research in this paper demonstrate that the proposed approach has broad prospects in tool wear condition monitoring.

Tool wear condition monitoring method based on graph neural network with a single sensor

Tool wear condition monitoring (TCM) is an important part of machining automation. In recent years, deep learning (DL)-based TCM methods have been widely researched. However, almost all DL-based methods need sufficient learning samples to obtain good accuracy, which is hard for TCM in terms of cost and time. In order to enhance the recognition accuracy of DL-based TCM under small samples, this paper proposed a new improved multi-scale edge-labelling graph neural network (MEGNN). Firstly, the signal of cutting force sensor is expanded to multi-dimensional data through phase space reconstruction. Secondly, these multi-dimensional data are encoded into a recurrence plot (RP). Then, the RP is input to multi-scale EGNN (MEGNN) to extract features. Finally, the tool condition is estimated through the updated edge labels using a weighted voting method. Our milling TCM experiments demonstrate the proposed MEGNN-based TCM method outperforms three DL-based methods under small samples.

A new tool wear condition monitoring method based on deep learning under small samples

Tool wear condition monitoring (TCM) is an important part of machining automation. In recent years, deep learning (DL) based TCM methods have been widely researched. However, almost DL-based methods need sufficient learning samples to obtain good accuracy, which is hard for TCM in terms of cost and time. In order to enhance the recognition accuracy of DL-based TCM under small samples, this paper proposed a new improved multi- scale edge-labeling graph neural network (MEGNN). Each channel signal of a cutting force sensor is expanded to multi- dimensional data through phase space reconstruction. Then, these multi- dimensional data are encoded into a gray recurrence plot (RP), and aggregated into a color RP, which is input to MEGNN to extract features for establishing a fully connected graph. Finally, the tool wear condition is estimated through the updated edge labels using a weighted voting method. Applications of the proposed MEGNN- based method to PHM 2010 milling TCM dataset and our experiments demonstrate it outperforms three DL-based methods (CNN, AlexNet, ResNet) under small samples.

System for Tool-Wear Condition Monitoring in CNC Machines under Variations of Cutting Parameter Based on Fusion Stray Flux-Current Processing.

The computer numerical control (CNC) machine has recently taken a fundamental role in the manufacturing industry, which is essential for the economic development of many countries. Current high quality production standards, along with the requirement for maximum economic benefits, demand the use of tool condition monitoring (TCM) systems able to monitor and diagnose cutting tool wear. Current TCM methodologies mainly rely on vibration signals, cutting force signals, and acoustic emission (AE) signals, which have the common drawback of requiring the installation of sensors near the working area, a factor that limits their application in practical terms. Moreover, as machining processes require the optimal tuning of cutting parameters, novel methodologies must be able to perform the diagnosis under a variety of cutting parameters. This paper proposes a novel non-invasive method capable of automatically diagnosing cutting tool wear in CNC machines under the variation of cutting speed and feed rate cutting parameters. The proposal relies on the sensor information fusion of spindle-motor stray flux and current signals by means of statistical and non-statistical time-domain parameters, which are then reduced by means of a linear discriminant analysis (LDA); a feed-forward neural network is then used to automatically classify the level of wear on the cutting tool. The proposal is validated with a Fanuc Oi mate Computer Numeric Control (CNC) turning machine for three different cutting tool wear levels and different cutting speed and feed rate values.