DOE OSTI2022
Tool condition monitoring (TCM) is an essential research area for the optimization and automation of metal machining processes, and could help manufacturers reduce costs, production time, machine downtime, energy use, and part scrappage. However, TCM systems developed in prior studies have struggled to reach the high level of generalizability which is necessary for industrial applications. This study addresses TCM system generalizability to new machining conditions, how variations in machining and environmental conditions may be used to improve model generalizability, and ensemble machine learning techniques for TCM. Further, milling tool life experiments were conducted using various machining conditions, and the processes' sound, spindle power, and axial load signals were collected. Different machine learning models were evaluated for the prediction of tool wear levels, including four individual models and five ensemble models. Changes in cutting speed were found to display a large effect on model performance, while the chip load showed some effect, and the feed rate had little effect. A simulated noise data augmentation technique for model improvement is applied within TCM for the first time, and resulted in increased model generalizability and reduced overfitting. Across several performance metrics the extremely randomized trees ensemble machine learning model generally performed the best for this application, achieving a leave-one-group-out cross validation accuracy score of 92.4 %, a 10-fold cross validation score of 98.9 %, and an averaged accuracy across 11 generalizability tests of 87.3 %.