2022
Pimenov, Danil Yurievich; Bustillo, Andrés; Wojciechowski, Szymon; Sharma, Vishal Santosh; Gupta, Munish Kumar; Kuntğlu, Mustafa
Artificial intelligence systems for tool condition monitoring in machining: analysis and critical review Journal Article
In: Journal of Intelligent Manufacturing, vol. 2022, 2022, ISSN: 0956-5515.
Abstract | Links | BibTeX | Tags: Artificial intelligence, Machining, Sensor, tool condition monitoring, Tool life, Wear
@article{Pimenov2022,
title = {Artificial intelligence systems for tool condition monitoring in machining: analysis and critical review},
author = {Danil Yurievich Pimenov and Andrés Bustillo and Szymon Wojciechowski and Vishal Santosh Sharma and Munish Kumar Gupta and Mustafa Kuntğlu},
url = {https://link.springer.com/article/10.1007/s10845-022-01923-2#citeas},
doi = {10.1007/s10845-022-01923-2},
issn = {0956-5515},
year = {2022},
date = {2022-03-12},
journal = {Journal of Intelligent Manufacturing},
volume = {2022},
abstract = {The wear of cutting tools, cutting force determination, surface roughness variations and other machining responses are of keen interest to latest researchers. The variations of these machining responses results in change in dimensional accuracy and productivity upto great extent. In addition, an excessive increase in wear leads to catastrophic consequences, exceeding the tool breakage. Therefore, this article discusses the online trend of modern approaches in tool condition monitoring while different machining operations. For this purpose, the effective use of new sensors and artificial intelligence (AI) is considered and followed during this holistic review work. The sensor systems used for monitoring tool wear are dynamometers, accelerometers, acoustic emission sensors, current and power sensors, image sensors, other sensors. These systems allow to solve the problem of automation and modeling of technological parameters of the main types of cutting, such as turning, milling, drilling and grinding. The modern artificial intelligence methods are considered, such as: Neural networks, Image recognition, Fuzzy logic, Adaptive neuro-fuzzy inference systems, Bayesian Networks, Support vector machine, Ensembles, Decision and regression trees, k-nearest neighbors, Artificial Neural Network, Markov model, Singular Spectrum Analysis, Genetic algorithms. Discussions also includes the main advantages, disadvantages and prospects of using various AI methods for tool wear monitoring. Moreover, the problems and future directions of the main processing methods using AI models are also highlighted.},
keywords = {Artificial intelligence, Machining, Sensor, tool condition monitoring, Tool life, Wear},
pubstate = {published},
tppubtype = {article}
}
The wear of cutting tools, cutting force determination, surface roughness variations and other machining responses are of keen interest to latest researchers. The variations of these machining responses results in change in dimensional accuracy and productivity upto great extent. In addition, an excessive increase in wear leads to catastrophic consequences, exceeding the tool breakage. Therefore, this article discusses the online trend of modern approaches in tool condition monitoring while different machining operations. For this purpose, the effective use of new sensors and artificial intelligence (AI) is considered and followed during this holistic review work. The sensor systems used for monitoring tool wear are dynamometers, accelerometers, acoustic emission sensors, current and power sensors, image sensors, other sensors. These systems allow to solve the problem of automation and modeling of technological parameters of the main types of cutting, such as turning, milling, drilling and grinding. The modern artificial intelligence methods are considered, such as: Neural networks, Image recognition, Fuzzy logic, Adaptive neuro-fuzzy inference systems, Bayesian Networks, Support vector machine, Ensembles, Decision and regression trees, k-nearest neighbors, Artificial Neural Network, Markov model, Singular Spectrum Analysis, Genetic algorithms. Discussions also includes the main advantages, disadvantages and prospects of using various AI methods for tool wear monitoring. Moreover, the problems and future directions of the main processing methods using AI models are also highlighted.
2020
Bustillo, Andrés; Pimenov, Danil Yurievich; Mia, Mozammel; Kapłonek, Wojciech
Machine-learning for automatic prediction of flatness deviation considering the wear of the face mill teeth Journal Article
In: Journal of Intelligent Manufacturing, 2020, ISSN: 0956-5515.
Abstract | Links | BibTeX | Tags: Cutting power, Face milling, Flatness deviation, Random forest, SMOTE, tool condition monitoring, Tool life, Wear
@article{Bustillo2020b,
title = {Machine-learning for automatic prediction of flatness deviation considering the wear of the face mill teeth},
author = {Andrés Bustillo and Danil Yurievich Pimenov and Mozammel Mia and Wojciech Kapłonek},
url = {https://link.springer.com/article/10.1007/s10845-020-01645-3},
doi = {https://doi.org/10.1007/s10845-020-01645-3},
issn = {0956-5515},
year = {2020},
date = {2020-09-03},
journal = {Journal of Intelligent Manufacturing},
abstract = {The acceptance of the machined surfaces not only depends on roughness parameters but also in the flatness deviation (Δfl). Hence, before reaching the threshold of flatness deviation caused by the wear of the face mill, the tool inserts need to be changed to avoid the expected product rejection. As current CNC machines have the facility to track, in real-time, the main drive power, the present study utilizes this facility to predict the flatness deviation—with proper consideration to the amount of wear of cutting tool insert’s edge. The prediction of deviation from flatness is evaluated as a regression and a classification problem, while different machine-learning techniques like Multilayer Perceptrons, Radial Basis Functions Networks, Decision Trees and Random Forest ensembles have been examined. Finally, Random Forest ensembles combined with Synthetic Minority Over-sampling Technique (SMOTE) balancing technique showed the highest performance when the flatness levels are discretized taking into account industrial requirements. The SMOTE balancing technique resulted in a very useful strategy to avoid the strong limitations that small experiment datasets produce in the accuracy of machine-learning models.},
keywords = {Cutting power, Face milling, Flatness deviation, Random forest, SMOTE, tool condition monitoring, Tool life, Wear},
pubstate = {published},
tppubtype = {article}
}
The acceptance of the machined surfaces not only depends on roughness parameters but also in the flatness deviation (Δfl). Hence, before reaching the threshold of flatness deviation caused by the wear of the face mill, the tool inserts need to be changed to avoid the expected product rejection. As current CNC machines have the facility to track, in real-time, the main drive power, the present study utilizes this facility to predict the flatness deviation—with proper consideration to the amount of wear of cutting tool insert’s edge. The prediction of deviation from flatness is evaluated as a regression and a classification problem, while different machine-learning techniques like Multilayer Perceptrons, Radial Basis Functions Networks, Decision Trees and Random Forest ensembles have been examined. Finally, Random Forest ensembles combined with Synthetic Minority Over-sampling Technique (SMOTE) balancing technique showed the highest performance when the flatness levels are discretized taking into account industrial requirements. The SMOTE balancing technique resulted in a very useful strategy to avoid the strong limitations that small experiment datasets produce in the accuracy of machine-learning models.
2017
Rodríguez, Juan José; Quintana, Guillem; Bustillo, Andrés; Ciurana, Joaquim
A decision-making tool based on decision trees for roughness prediction in face milling Journal Article
In: International Journal of Computer Integrated Manufacturing, vol. 30, no. 9, 2017, ISSN: 0951-192X.
Abstract | Links | BibTeX | Tags: AI in manufacturing systems, cost management, decision support systems, Decision trees, process control, surface roughness, tool condition monitoring
@article{Rodríguez2017,
title = {A decision-making tool based on decision trees for roughness prediction in face milling},
author = {Juan José Rodríguez and Guillem Quintana and Andrés Bustillo and Joaquim Ciurana},
url = {https://www.tandfonline.com/doi/full/10.1080/0951192X.2016.1247991},
doi = {10.1080/0951192X.2016.1247991},
issn = {0951-192X},
year = {2017},
date = {2017-01-01},
journal = {International Journal of Computer Integrated Manufacturing},
volume = {30},
number = {9},
abstract = {The selection of the right cutting tool in manufacturing process design is always an open question, especially when different tools are available on the market with similar characteristics, but marked differences in price, ranging from low-cost to high-performance cutting tools. The ultimate decision of the engineer will depend on previous experience with the life cycle of the tool and its performance, but without the support of a systematic knowledge base. This research presents a decision-making system based on soft-computing techniques. First, several experiments were carried out with four different cutting tools: two flat-milling low-cost tools without any surface treatment or coating and two high-performance, high-cost cutting tools (in both cases with four cutting edges, similar geometrical features and diameters). Three different measures of tool wear are considered in the context of real workshop conditions: on-line power consumption, cutting length and volume of cut material. Finally, decision trees have been selected as the most suitable technique for building a decision-making system for two reasons: these trees show higher accuracy for the prediction of roughness in terms of tool wear and tool type. They also provide useful visual feedback on the information that is extracted from the real data, which can be directly used by the process engineer.},
keywords = {AI in manufacturing systems, cost management, decision support systems, Decision trees, process control, surface roughness, tool condition monitoring},
pubstate = {published},
tppubtype = {article}
}
The selection of the right cutting tool in manufacturing process design is always an open question, especially when different tools are available on the market with similar characteristics, but marked differences in price, ranging from low-cost to high-performance cutting tools. The ultimate decision of the engineer will depend on previous experience with the life cycle of the tool and its performance, but without the support of a systematic knowledge base. This research presents a decision-making system based on soft-computing techniques. First, several experiments were carried out with four different cutting tools: two flat-milling low-cost tools without any surface treatment or coating and two high-performance, high-cost cutting tools (in both cases with four cutting edges, similar geometrical features and diameters). Three different measures of tool wear are considered in the context of real workshop conditions: on-line power consumption, cutting length and volume of cut material. Finally, decision trees have been selected as the most suitable technique for building a decision-making system for two reasons: these trees show higher accuracy for the prediction of roughness in terms of tool wear and tool type. They also provide useful visual feedback on the information that is extracted from the real data, which can be directly used by the process engineer.