Bagging-gradient boosting decision tree based milling cutter wear status prediction modelling

Aiming to monitor wear condition of milling cutters in time and provide tool change decisions to ensure manufacturing safety and product quality, a tool wear monitoring model based on Bagging-Gradient Boosting Decision Tree (Bagging-GBDT) is proposed. In order to avoid incomplete tool state information contained in a single domain feature parameter, a multi-domain combination method is used to extract candidate characteristic parameter sets from time domain, frequency domain, and time–frequency domain. Then top 21 significant features are screened by eXtreme Gradient Boosting selection method. Synthetic Minority Oversampling Technique technology is integrated during feature selection to overly sample feature vectors, so that wear condition categories can be well balanced. Bagging idea is then introduced for parallel calculation of the gradient boosting decision tree and to improve its generalization ability. A Bagging-GBDT milling cutter wear condition prediction model is constructed and verified by public ball-end milling data set. Experiments show that random features and training samples selection can effectively improve prediction performance and generalization ability of prediction model. Our Bagging-GBDT model gains F1 score of 0.99350, which is 0.2% and 13.2% higher than the random forest algorithm and basic GBDT model, respectively.

Woodworking Tool Wear Condition Monitoring during Milling Based on Power Signals and a Particle Swarm Optimization-Back Propagation Neural Network

In the intelligent manufacturing of furniture, the power signal has the characteristics of low cost and high accuracy and is often used as a tool wear condition monitoring signal. However, the power signal is not very sensitive to tool wear conditions. The present work addresses this issue by proposing a novel woodworking tool wear condition monitoring method that employs a limiting arithmetic average filtering method and particle swarm optimization (PSO)-back propagation (BP) neural network algorithm. The limiting arithmetic average filtering method was used to process the power signal and extracted the features of the woodworking tool wear conditions. The spindle speed, depths of milling, features and tool wear conditions were used as sample vectors. The PSO-BP neural network algorithm was used to establish the monitoring model of the woodworking tool wear condition. Experiments show that the proposed limiting arithmetic average filtering method and PSO-BP neural network algorithm can accurately monitor the woodworking tool wear conditions under different milling parameters.

Use of the K-Nearest Neighbour Classifier in Wear Condition Classification of a Positive Displacement Pump

This paper presents a learning system with a K-nearest neighbour classifier to classify the wear condition of a multi-piston positive displacement pump. The first part reviews current built diagnostic methods and describes typical failures of multi-piston positive displacement pumps and their causes. Next is a description of a diagnostic experiment conducted to acquire a matrix of vibration signals from selected locations in the pump body. The measured signals were subjected to time-frequency analysis. The signal features calculated in the time and frequency domain were grouped in a table according to the wear condition of the pump. The next step was to create classification models of a pump wear condition and assess their accuracy. The selected model, which best met the set criteria for accuracy assessment, was verified with new measurement data. The article ends with a summary.

Tool wear condition monitoring in milling process based on data fusion enhanced long short-term memory network under different cutting conditions

Tool wear condition monitoring (TCM) is essential for milling process to ensure the machining quality, and the long short-term memory network (LSTM) is a good choice for predicting tool wear value. However, the robustness of LSTM- based method is poor when cutting condition changes. A novel method based on data fusion enhanced LSTM is proposed to estimate tool wear value under different cutting conditions. Firstly, vibration time series signal collected from milling process are transformed to feature space through empirical mode decomposition, variational mode decomposition and fourier synchro squeezed transform. And then few feature series are selected by neighborhood component analysis to reduce dimension of the signal features. Finally, these selected feature series are input to train the bidirectional LSTM network and estimate tool wear value. Applications of the proposed method to milling TCM experiments demonstrate it outperforms significantly SVR- based and RNN- based methods under different cutting conditions.

Investigation of Lateral Confinement, Roller Aspect Ratio and Wear Condition on HPGR Performance Using DEM-MBD-PRM Simulations

It has been known that the performance of high-pressure grinding rolls (HPGR) varies as a function of the method used to laterally confine the rolls, their diameter/length (aspect) ratio as well as their condition, if new or worn. However, quantifying these effects through direct experimentation in machines with reasonably large dimensions is not straightforward, given the challenge, among others, of guaranteeing that the feed material remains unchanged. The present work couples the discrete element method (DEM) to multibody dynamics (MBD) and a novel particle replacement model (PRM) to simulate the performance of a pilot-scale HPGR grinding pellet feed. It shows that rotating side plates, in particular when fitted with studs, will result in more uniform forces along the bed, which also translates in a more constant product size along the rolls as well as higher throughput. It also shows that the edge effect is not affected by roll length, leading to substantially larger proportional edge regions for high-aspect ratio rolls. On the other hand, the product from the center region of such rolls was found to be finer when pressed at identical specific forces. Finally, rolls were found to have higher throughput, but generate a coarser product when worn following the commonly observed trapezoidal profile. The approach often used in industry to compensate for roller wear is to increase the specific force and roll speed. It has been demonstrated to be effective in maintaining product fineness and throughput, as long as the minimum safety gap is not reached.