Advances in Manufacturing ›› 2024, Vol. 12 ›› Issue (1): 76-93.doi: 10.1007/s40436-023-00451-3

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Novel intelligent reasoning system for tool wear prediction and parameter optimization in intelligent milling

Long-Hua Xu1, Chuan-Zhen Huang1, Zhen Wang1, Han-Lian Liu2, Shui-Quan Huang1, Jun Wang3   

  1. 1. School of Mechanical Engineering, Yanshan University, Qinhuangdao, 066004, Hebei, People's Republic of China;
    2. Center for Advanced Jet Engineering Technologies (CaJET), Key Laboratory of High-efficiency and Clean Mechanical Manufacture (Ministry of Education), National Experimental Teaching Demonstration Center for Mechanical Engineering (Shandong University), School of Mechanical Engineering, Shandong University, Jinan, 250061, People's Republic of China;
    3. Institute of Manufacturing Technology, Guangdong University of Technology, Guangzhou, 510006, People's Republic of China
  • Received:2022-09-10 Revised:2022-11-10 Published:2024-03-14
  • Contact: Chuan-Zhen Huang,E-mail:huangchuanzhen@ysu.edu.cn E-mail:huangchuanzhen@ysu.edu.cn
  • Supported by:
    This work was financially supported by the National Natural Science Foundation of China (Grant No. 52275464), the Natural Science Foundation for Young Scientists of Hebei Province (Grant No. E2022203125), the Scientific Research Project for National High-level Innovative Talents of Hebei Province Full-time Introduction (Grant No. 2021HBQZYCXY004), and the National Natural Science Foundation of China (Grant No. 52075300).

Abstract: Accurate intelligent reasoning systems are vital for intelligent manufacturing. In this study, a new intelligent reasoning system was developed for milling processes to accurately predict tool wear and dynamically optimize machining parameters. The developed system consists of a self-learning algorithm with an improved particle swarm optimization (IPSO) learning algorithm, prediction model determined by an improved case-based reasoning (ICBR) method, and optimization model containing an improved adaptive neural fuzzy inference system (IANFIS) and IPSO. Experimental results showed that the IPSO algorithm exhibited the best global convergence performance. The ICBR method was observed to have a better performance in predicting tool wear than standard CBR methods. The IANFIS model, in combination with IPSO, enabled the optimization of multiple objectives, thus generating optimal milling parameters. This paper offers a practical approach to developing accurate intelligent reasoning systems for sustainable and intelligent manufacturing.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00451-3

Key words: Improved particle swarm optimization (IPSO) algorithm, Improved case-based reasoning (ICBR) method, Adaptive neural fuzzy inference system (ANFIS) model, Tool wear prediction, Intelligent manufacturing