Prediction of tool wear in milling process based on BP neural network optimized by firefly algorithm

• Published in: Proceedings of the Institution of Mechanical Engineers. Part E, Journal of process mechanical engineering Journal of process mechanical engineering, 2024-10, Vol.238 (5), p.2387-2403
• Main Authors: Cheng, Yao-Nan, Jin, Ying-Bo, Gai, Xiao-Yu, Guan, Rui, Lu, Meng-Da
• Format: Article
• Language: English
• Subjects: Algorithms; Back propagation networks; Correlation coefficients; Cutting force; Cutting parameters; Cutting tools; Cutting wear; Efficiency; Feature extraction; Frequency domain analysis; Genetic algorithms; Heuristic methods; Impact prediction; Intelligent manufacturing systems; Milling (machining); Network reliability; Neural networks; Noise reduction; Noise threshold; Particle swarm optimization; Prediction models; Time domain analysis; Tool wear; Wavelet analysis; Wavelet transforms; Workpieces
• ISSN: 0954-4089; 2041-3009
• DOI: 10.1177/09544089231160492

Long-time discontinuous contact is easy to cause tool wear during milling. To decrease the impact of severe wear on workpiece quality and processing efficiency, cutting tools should be replaced timely. Therefore, tool wear prediction is an important aspect in improving process efficiency, ensuring machining precision and realizing intelligent manufacturing. To boost the precision of online prediction of tool wear, this paper suggests a novel approach to monitor tool wear by optimizing backpropagation (BP) neural network via firefly algorithm (FA). Specifically, the progressive semi-soft threshold function is applied to the process of cutting force signal noise reduction, which reduces redundant signals and noise interference in the signal. Time-domain analysis, frequency-domain analysis, and wavelet packet decomposition are utilized, cutting force features are extracted, and Pearson correlation coefficient is used to sift out signal features that are highly connected to tool wear. The FA is used to improve the BP neural network's weights and thresholds. Through learning nonlinear mapping, relationship between tool flank wear and signal features is realized. A prediction model of tool wear of FA-BP is constructed. Milling experiments validate the prediction model in the milling process. The experimental outcomes confirm the precision and reliability of the method. In comparison to BP neural network, genetic algorithm optimized BP neural network and particle swarm optimization algorithm optimized BP neural network prediction method, it has a greater prediction accuracy and a stronger training impact, and has superior performance. The research results can give a theoretical foundation and technological assistance for predicting tool wear, which is crucial for improving workpiece quality, processing efficiency, and promoting intelligent development.