Accurate tool wear prediction is essential for maintaining productivity and minimizing costs in machining. However, the complex nature of the tool wear process poses significant challenges to achieving reliable predictions. This study explores data-driven methods, in particular deep learning, for tool wear prediction. Traditional data-driven approaches often focus on a single process, relying on multi-sensor setups and extensive data generation, which limits generalization to new settings. Moreover, multi-sensor integration is often impractical in industrial environments. To address these limitations, this research investigates the transferability of predictive models using minimal training data, validated across two processes. Furthermore, it uses a simple setup with a single acceleration sensor to establish a low-cost data generation approach that facilitates the generalization of models to other processes via transfer learning. The study evaluates several machine learning models, including convolutional neural networks (CNN), long short-term memory networks (LSTM), support vector machines (SVM) and decision trees, trained on different input formats such as feature vectors and short-time Fourier transform (STFT). The performance of the models is evaluated on different amounts of training data, including scenarios with significantly reduced datasets, providing insight into their effectiveness under constrained data conditions. The results demonstrate the potential of specific models and configurations for effective tool wear prediction, contributing to the development of more adaptable and efficient predictive maintenance strategies in machining. Notably, the ConvNeXt model has an exceptional performance, achieving an 99.1% accuracy in identifying tool wear using data from only four milling tools operated until they are worn.

As an integral part of contemporary manufacturing, monitoring systems obtain valuable information during machining to oversee the condition of both the process and the machine. Recently, diverse algorithms have been employed to detect tool wear using single or multiple sources of measurements. In this study, a deep learning approach is proposed for estimating tool wear, considering cutting parameters. The model's accuracy and transferability in tool wear estimation were assessed with milling experiments conducted under varying cutting parameters. The results indicate that the proposed method outperforms conventional methods in terms of both transferability and rapid learning capabilities.

Tool wear conditions impact the final quality of the workpiece. In this study, we propose a deep learning approach based on a convolutional neural network that incorporates cutting conditions as extra model inputs, aiming to improve tool wear estimation accuracy and fulfill industrial demands for zero-shot transferability. Through a series of milling experiments under various cutting parameters, we evaluate the model's performance in terms of tool wear estimation accuracy and its transferability to new fixed or variable cutting parameters. The results consistently highlight our approach's advantage over conventional models that omit cutting conditions, maintaining superior performance irrespective of the stability of the wear development or the limitation of the training dataset. This finding underscores its potential applicability in industrial scenarios.

This paper introduces a novel method for predicting tool wear in CNC turning operations, combining ultrasonic microphone arrays and convolutional neural networks (CNNs). High-frequency acoustic emissions between 0 kHz and 60 kHz are enhanced using beamforming techniques to improve the signal- to-noise ratio. The processed acoustic data is then analyzed by a CNN, which predicts the Remaining Useful Life (RUL) of cutting tools. Trained on data from 350 workpieces machined with a single carbide insert, the model can accurately predict the RUL of the carbide insert. Our results demonstrate the potential gained by integrating advanced ultrasonic sensors with deep learning for accurate predictive maintenance tasks in CNC machining.

In this paper, a new system based on combinations of a shape descriptor and a contour descriptor has been proposed for classifying inserts in milling processes according to their wear level following a computer vision based approach. To describe the wear region shape we have proposed a new descriptor called ShapeFeat and its contour has been characterized using the method BORCHIZ that, to the best of our knowledge, achieves the best performance for tool wear monitoring following a computer vision-based approach. Results show that the combination of BORCHIZ with ShapeFeat using a late fusion method improves the classification performance significantly, obtaining an accuracy of 91.44% in the binary classification (i.e. the classification of the wear as high or low) and 82.90% using three target classes (i.e. classification of the wear as high, medium or low). These results outperform the ones obtained by both descriptors used on their own, which achieve accuracies of 88.70 and 80.67% for two and three classes, respectively, using ShapeFeat and 87.06 and 80.24% with B-ORCHIZ. This study yielded encouraging results for the manufacturing community in order to classify automatically the inserts in terms of their wear for milling processes.

In this work we propose a new online, low cost and fast approach based on computer vision and machine learning to determine whether cutting tools used in edge profile milling processes are serviceable or disposable based on their wear level. We created a new dataset of 254 images of edge profile cutting heads which is, to the best of our knowledge, the first publicly available dataset with enough quality for this purpose. All the inserts were segmented and their cutting edges were cropped, obtaining 577 images of cutting edges: 301 functional and 276 disposable. The proposed method is based on (1) dividing the cutting edge image in different regions, called Wear Patches (WP), (2) characterising each one as worn or serviceable using texture descriptors based on different variants of Local Binary Patterns (LBP) and (3) determine, based on the state of these WP, if the cutting edge (and, therefore, the tool) is serviceable or disposable. We proposed and assessed five different patch division configurations. The individual WP were classified by a Support Vector Machine (SVM) with an intersection kernel. The best patch division configuration and texture descriptor for the WP achieves an accuracy of 90.26% in the detection of the disposable cutting edges. These results show a very promising opportunity for automatic wear monitoring in edge profile milling processes.

The prediction of tool wear helps minimize costs and enhance product quality in manufacturing. While existing data-driven models using machine learning and deep learning have contributed to the accurate prediction of tool wear, they often lack generality and require substantial training data for high accuracy. In this paper, we propose a new data-driven model that uses Bayesian Regularized Artificial Neural Networks (BRANNs) to precisely predict milling tool wear. BRANNs combine the strengths and leverage the benefits of artificial neural networks (ANNs) and Bayesian regularization, whereby ANNs learn complex patterns and Bayesian regularization handles uncertainty and prevents overfitting, resulting in a more generalized model. We treat both process parameters and monitoring sensor signals as BRANN input parameters. We conducted an extensive experimental study featuring four different experimental data sets, including the NASA Ames milling dataset, the 2010 PHM Data Challenge dataset, the NUAA Ideahouse tool wear dataset, and an in-house performed end-milling of the Ti6Al4V dataset. We inspect the impact of input features, training data size, hidden units, training algorithms, and transfer functions on the performance of the proposed BRANN model and demonstrate that it outperforms existing state-of-the-art models in terms of accuracy and reliability.

At present, most surface-quality prediction methods can only perform single-task prediction which results in under-utilised datasets, repetitive work and increased experimental costs. To counter this, the authors propose a Bayesian hierarchical model to predict surface-roughness measurements for a turning machining process. The hierarchical model is compared to multiple independent Bayesian linear regression models to showcase the benefits of partial pooling in a machining setting with respect to prediction accuracy and uncertainty quantification.

Tool flank wear monitoring can minimize machining downtime costs while increasing productivity and product quality. In some industrial applications, only a limited level of tool wear is allowed to attain necessary tolerances. It may become challenging to monitor a limited level of tool wear in the data collected from the machine due to the other components, such as the flexible vibrations of the machine, dominating the measurement signals. In this study, a tool wear monitoring technique to predict limited levels of tool wear from the spindle motor current and dynamometer measurements is presented. High-frequency spindle motor current data is collected with an industrial edge device while the cutting forces and torque are measured with a rotary dynamometer in drilling tests for a selected number of holes. Feature engineering is conducted to identify the statistical features of the measurement signals that are most sensitive to small changes in tool wear. A neural network based on the long short-term memory (LSTM) architecture is developed to predict tool flank wear from the measured spindle motor current and dynamometer signals. It is demonstrated that the proposed technique predicts tool flank wear with good accuracy and high computational efficiency. The proposed technique can easily be implemented in an industrial edge device as a real-time predictive maintenance application to minimize the costs due to manufacturing downtime and tool underuse or overuse.

Blanking processes belong to the most widely used manufacturing techniques due to their economic efficiency. Their economic viability depends to a large extent on the resulting product quality and the associated customer satisfaction as well as on possible downtimes. In particular, the occurrence of increased tool wear reduces the product quality and leads to downtimes, which is why considerable research has been carried out in recent years with regard to wear detection. While processes have widely been monitored based on force and acceleration signals, a new approach is pursued in this paper. Blanked workpieces manufactured by punches with 16 different wear states are photographed and then used as inputs for Deep Convolutional Neural Networks to classify wear states. The results show that wear states can be predicted with surprisingly high accuracy, opening up new possibilities and research opportunities for tool wear monitoring of blanking processes.