Tool wear monitoring is a typical multi-sensor information fusion task. The handcrafted features may be a suboptimal choice that will lower the monitoring accuracy and require significant computational costs that hinder the real-time applications. In order to solve these problems, this paper proposed a new multisensory data-driven tool wear predicting method based on reshaped time series convolutional neural network (RTSCNN). In this method, the reshaped time series layer is introduced to represent the multisensory raw signals, the alternately convolutional and pooling layers is employed to adaptively learn distinctive characteristics of tool wear directly from multisensory raw signals while the multi-layer perceptron with regression layer performs automatic tool wear prediction. In addition, three tool run-to-failure datasets measured from three-flute ball nose tungsten carbide cutter of high-speed CNC machine under milling operations are used to experimentally demonstrate the performance of the proposed RTSCNN-based multisensory data-driven tool wear predicting method. The experimental results show that the prediction error of the RTSCNN-based data-driven method is observably lower than other state-of-art methods.INDEX TERMS Tool wear predicting, multi-sensor, raw signals, convolutional neural network, reshaped time series, manufacturing.
Tool wear monitoring is essential in precision manufacturing to improve surface quality, increase machining efficiency, and reduce manufacturing cost. Although tool wear can be reflected by measurable signals in automatic machining operations, with the increase of collected data, features are manually extracted and optimized, which lowers monitoring efficiency and increases prediction error. For addressing the aforementioned problems, this paper proposes a tool wear monitoring method using vibration signal based on short-time Fourier transform (STFT) and deep convolutional neural network (DCNN) in milling operations. First, the image representation of acquired vibration signals is obtained based on STFT, and then the DCNN model is designed to establish the relationship between obtained time-frequency maps and tool wear, which performs adaptive feature extraction and automatic tool wear prediction. Moreover, this method is demonstrated by employing three tool wear experimental datasets collected from three-flute ball nose tungsten carbide cutter of a high-speed CNC machine under dry milling. Finally, the experimental results prove that the proposed method is more accurate and relatively reliable than other compared methods.
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