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2 Journal of Machine Engineering

2 2023

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An application of machine learning methods to cutting tool path clustering and rul estimation in machining

Zegarra Fabio C., Vargas-Machuca Juan, Roman-Gonzalez Avid, Coronado Alberto M.

Journal of Machine Engineering

2023

Vol. 23, No. 4

5--17

Machine learning has been widely used in manufacturing, leading to significant advances in diverse problems, including the prediction of wear and remaining useful life (RUL) of machine tools. However, the data used in many cases correspond to simple and stable processes that differ from practical applications. In this work, a novel dataset consisting of eight cutting tools with complex tool paths is used. The time series of the tool paths, corresponding to the three-dimensional position of the cutting tool, are grouped according to their shape. Three unsupervised clustering techniques are applied, resulting in the identification of DBA-k-means as the most appropriate technique for this case. The clustering process helps to identify training and testing data with similar tool paths, which is then applied to build a simple two-feature prediction model with the same level of precision for RUL prediction as a more complex four-feature prediction model. This work demonstrates that by properly selecting the methodology and number of clusters, tool paths can be effectively classified, which can later be used in prediction problems in more complex settings.

A comparative study of CNN, LSTM, BiLSTM, AND GRU architectures for tool wear prediction in milling processes

Zegarra Fabio C., Vargas-Machuca Juan, Coronado Alberto M.

Journal of Machine Engineering

2023

Vol. 23, No. 4

122--136

Accurately predicting machine tool wear requires models capable of capturing complex, nonlinear interactions in multivariate time series inputs. Recurrent neural networks (RNNs) are well-suited to this task, owing to their memory mechanisms and capacity to construct highly complex models. In particular, LSTM, BiLSTM, and GRU architectures have shown promise in wear prediction. This study demonstrates that RNNs can automatically extract relevant information from time series data, resulting in highly precise wear models with minimal feature engineering. Notably, this approach avoids the need for excessively large window sizes of data points during model training, which would increase model complexity and processing time. Instead, this study proposes a procedure that achieves low prediction errors with window sizes as small as 100 data points. By employing Bayesian hyperparameter optimization and two preprocessing techniques (detrend and offset), RMSE errors consistently fall below 10. A key difference in this study is the use of boxplots to provide a better representation of result variability, as opposed to solely reporting the best values. The proposed approach matches more complex state of-the-art. methods and offers a powerful tool for wear prediction in engineering applications.