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

  • Long-Hua Xu ,
  • Chuan-Zhen Huang ,
  • Zhen Wang ,
  • Han-Lian Liu ,
  • Shui-Quan Huang ,
  • Jun Wang
Expand
  • 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 date: 2022-09-10

  Revised date: 2022-11-10

  Online published: 2024-03-14

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

Cite this article

Long-Hua Xu , Chuan-Zhen Huang , Zhen Wang , Han-Lian Liu , Shui-Quan Huang , Jun Wang . Novel intelligent reasoning system for tool wear prediction and parameter optimization in intelligent milling[J]. Advances in Manufacturing, 2024 , 12(1) : 76 -93 . DOI: 10.1007/s40436-023-00451-3

References

1 Olsson M, Bushlya V, Lenrick F et al (2021) Evaluation of tool wear mechanisms and tool performance in machining single-phase tungsten. Int J Refract Met H 94:105379. https://doi.org/10.1016/j.ijrmhm.2020.105379
2 Zhuang K, Shi Z, Sun Y et al (2021) Digital twin-driven tool wear monitoring and predicting method for the turning process. Symmetry 13(8):1438. https://doi.org/10.3390/sym13081438
3 Denis B, Luiz CF, Bertrand SR (2020) Prediction of PCBN tool life in hard turning process based on the three-dimensional tool wear parameter. Int J Adv Manuf Tech 106(1):779–790
4 Marani M, Zeinali M, Kouam J et al (2020) Prediction of cutting tool wear during a turning process using artificial intelligence techniques. Int J Adv Manuf Tech 111(1):505–515
5 Seemuang N, McLeay T, Slatter T (2016) Using spindle noise to monitor tool wear in a turning process. Int J Adv Manuf Tech 86(12):2781–2790
6 Zhang B, Katinas C, Shin YC (2018) Robust tool wear monitoring using systematic feature selection in turning processes with consideration of uncertainties. J Manuf Sci E 140(8):081010. https://doi.org/10.1115/1.4040267
7 Gu DX, Liang CY, Bichindaritz I et al (2012) A case-based knowledge system for safety evaluation decision making of thermal power plants. Knowl-Based Syst 26(2):185–195
8 Yan A, Wang W, Zhang C et al (2014) A fault prediction method that uses improved case-based reasoning to continuously predict the status of a shaft furnace. Inf Sci 259(2):269–281
9 Zheng LV, Liu Y, Zhao J et al (2015) Soft computing for overflow particle size in grinding process based on hybrid case based reasoning. Appl Soft Comput 27:533–542
10 Wang H, Rong Y (2008) Case based reasoning method for computer aided welding fixture design. Comput Aided Des 40(12):1121–1132
11 Guo Y, Hu J, Peng Y (2011) Research on CBR system based on datamining. Appl Soft Comput 11(8):5006–5014
12 Han M, Cao ZJ (2015) An improved case-based reasoning method and its application in endpoint prediction of basic oxygen furnace. Neurocomputing 149:1245–1252
13 Fernandez RF, Diaz F, Corchado JM (2007) Reducing the memory size of a fuzzy case-based reasoning system applying rough set techniques. IEEE T Syst Man Cy 37(1):138–146
14 Han M, Shen LH (2011) Research of CBR based on particle swarm optimization. Control Decis 26(4):637–640
15 Hyuk I, Sang P (2007) Case-based reasoning and neural network based expert system for personalization. Expert Syst Appl 32(3):77–85
16 Relich M, Pawlewski P (2018) A case-based reasoning approach to cost estimation of new product development. Neurocomputing 272:40–45
17 Biswas SK, Sinha N, Purakayastha B et al (2014) Hybrid expert system using case based reasoning and neural network for classification. Biol Inspir Cogn Arc 9:57–70
18 Li GF, Gu YS, Kong JY et al (2012) Intelligent control of coke oven air-fuel ratio. Int Rev Comput Softw 7(13):1262–1267
19 Jung S, Lim T, Kim D (2009) Integrating radial basis function networks with case-based reasoning for product design. Expert Syst Appl 36:5695–5701
20 Xu L, Huang C, Li C et al (2020) A novel intelligent reasoning system to estimate energy consumption and optimize cutting parameters toward sustainable machining. J Clean Prod 261:121160. https://doi.org/10.1016/j.jclepro.2020.121160
21 Xu L, Huang C, Li C et al (2021) An improved case based reasoning method and its application in estimation of surface quality toward intelligent machining. J Intell Manuf 32(1):313–327
22 Hou L, Zhang H, Peng Y (2021) An integrated multi-objective optimization method with application to train crashworthiness design. Struct Multidiscip O 63(3):1513–1532
23 Luo JP, Yang Y, Liu Q et al (2018) A new hybrid memetic multi-objective optimization algorithm for multi-objective optimization. Inform Sci 448/449:164–186
24 Zhang Y, Gong DW, Sun XY et al (2017) A PSO-based multi-objective multilabel feature selection method in classification. Sci Rep 1:1–12
25 Saw LH, Ho LW, Yew MC et al (2018) Sensitivity analysis of drill wear and optimization using adaptive neuro fuzzy-genetic algorithm technique toward sustainable machining. J Clean Prod 172:3289–3298
26 Dong MG, Wang N (2011) Adaptive network-based fuzzy inference system with leave-one-out cross-validation approach for prediction of surface roughness. Appl Math Model 35:1024–1035
27 Ghosh N, Ravi YB, Patra A et al (2007) Estimation of tool wear during CNC milling using neural network-based sensor fusion. Mech Syst Signal Pr 21:466–479
28 Kaya B, Oysu C, Ertunc HM (2011) Force-torque based on-line tool wear estimation system for CNC milling of Inconel 718 using neural networks. Adv Eng Softw 42:76–84
29 Salgado DR, Alonso FJ (2007) An approach based on current and sound signals for in-process tool wear monitoring. Int J Mach Tool Manuf 47:2140–2152
30 Kong D, Chen Y, Li N et al (2016) Tool wear monitoring based on kernel principal component analysis and v-support vector regression. Int J Adv Manuf Tech 89:1–16
31 Sada SO, Lkpeseni SC (2021) Evaluation of ANN and ANFIS modeling ability in the prediction of AISI 1050 steel machining performance. Heliyon 7(2):e06136. https://doi.org/10.1016/j.heliyon.2021.e06136
32 Lv Z, Liu Y, Zhao J et al (2015) Soft computing for overflow particle size in grinding process based on hybrid case based reasoning. Appl Soft Comput 27:533–542
33 Rajendra P, Murthy KVN, Subbarao A et al (2019) Use of ANN models in the prediction of meteorological data. Model Earth Syst Env 5(3):1051–1058
34 Sharma H, Bansal JC, Arya KV (2014) Self balanced differential evolution. J Comput Sci 5:312–323
35 Jadid MN, Fairbairn DR (1996) Neural-network applications in predicting moment-curvature parameters from experimental data. Eng Appl Artif Intel 9(3):309–319
36 Tharwat A, Schenck W (2021) A conceptual and practical comparison of PSO-style optimization algorithms. Expert Syst Appl 167:114430. https://doi.org/10.1016/j.eswa.2020.114430
37 Zhuang XC, Yu TX, Sun ZC (2021) Wear prediction of a mechanism with multiple joints based on ANFIS. Eng Fail Anal 119:104958. https://doi.org/10.1016/j.engfailanal.2020.104958
38 Zhu X, Wang N (2022) Hairpin RNA genetic algorithm based ANFIS for modeling overhead cranes. Mech Syst Signal Pr 165:108326. https://doi.org/10.1016/j.ymssp.2021.108326
39 Mohammadi K, Shamshirband S, Petkovič D et al (2016) Using ANFIS for selection of more relevant parameters to predict dew point temperature. Appl Therm Eng 96:311–319
40 Xu LH, Huang CZ, Li CW et al (2022) Prediction of tool wear width size and optimization of cutting parameters in milling process using novel ANFIS-PSO method. Proc IMechE Part B J Eng Manuf 236(1/2):111–122
41 Ortner HM, Flege S, Heck M (2008) Analytical investigations concerning the wear behavior of cutting tools used for the machining of compacted graphite iron and grey cast iron. Int J Refract Met H 26:197–206
42 Bao GO, Mao KF (2009) Particle swarm optimization algorithm with asymmetric time varying acceleration coefficients. In: IEEE international conference on robotics and biomimetics. December 19–23, 2009, Guilin. https://doi.org/10.1109/ROBIO.2009.5420504
43 Uguz H (2014) A novel particle swarm optimization algorithm with levy flight. Appl Soft Comput 23:333–345
44 Deb K, Goyal M (1996) A combined genetic adaptive search (GeneAS) for engineering design. Comput Sci Inform 26:30–45
45 Chegini SN, Bagheri A, Najafi F (2018) PSOSCALF: a new hybrid PSO based on sine cosine algorithm and levy flight for solving optimization problems. Appl Soft Comput 73:697–726
46 Mirjalili SA, Mirjalili SM, Hatamlou A (2016) Multi-verse optimizer: a nature inspired algorithm for global optimization. Neural Comput Appl 27:495–513
47 Mirjalili SA (2016) SCA: a sine cosine algorithm for solving optimization problems. Knowl-Based Syst 96:120–133
Outlines

/