Machine-learning for automatic prediction of flatness deviation considering the wear of the face mill teeth

Andres Bustillo (), Danil Yu. Pimenov (), Mozammel Mia () and Wojciech Kapłonek ()
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Andres Bustillo: Universidad de Burgos
Danil Yu. Pimenov: South Ural State University
Mozammel Mia: Imperial College London
Wojciech Kapłonek: Koszalin University of Technology

Journal of Intelligent Manufacturing, 2021, vol. 32, issue 3, No 16, 895-912

Abstract: 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: Face milling; Wear; Tool life; Tool condition monitoring; Flatness deviation; Cutting power; Random forest; SMOTE (search for similar items in EconPapers)
Date: 2021
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Citations: View citations in EconPapers (4)

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DOI: 10.1007/s10845-020-01645-3

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