A Hybrid Approach to Cutting Tool Remaining Useful Life Prediction Based on the Wiener Process

• Published in: IEEE transactions on reliability 2018-09, Vol.67 (3), p.1294-1303
• Main Authors: Sun, Huibin, Cao, Dali, Zhao, Zidong, Kang, Xia
• Format: Article
• Language: English
• Subjects: Acoustic emission; Back propagation networks; Cutting tools; Cutting wear; Data-driven model; Degradation; Hidden Markov models; hybrid prognostics; Life prediction; Machining; Mathematical models; Neural networks; Performance enhancement; Physics; physics-based model; Predictive models; Prognostics and health management; Propagation modes; remaining useful life (RUL); Tool life; Tool wear; Useful life; Wiener process
• ISSN: 0018-9529; 1558-1721
• DOI: 10.1109/TR.2018.2831256

Accurate remaining useful life prediction is meaningful for cutting tool usability evaluation. Over the years, experience-based models, data-driven models, and physics-based models have been used individually to predict cutting tool remaining useful lives. In order to improve prediction performances, different prognostics models can be combined to leverage their advantages. In this paper, a hybrid cutting tool remaining useful life prediction approach is proposed by combining a data-driven model and a physics-based model. By using force, vibration and acoustic emission signals, the data-driven model monitors cutting tool wear conditions based on empirical mode decomposition and back propagation neural network. On the basis of the Wiener process, the physics-based model builds a cutting tool condition degradation model to predict cutting tool remaining useful lives. Experimental study verifies the approach's effectiveness, accuracy, and robustness. Then, cutting tool remaining useful lives can be predicted more accurately during the machining process.