Physics-informed Gaussian process for tool wear prediction

• Published in: ISA transactions 2023-12, Vol.143, p.548-556
• Main Authors: Zhu, Kunpeng, Huang, Chengyi, Li, Si, Lin, Xin
• Format: Article
• Language: English
• Subjects: Extrapolation prediction; Gaussian process; Physical model; Tool condition monitoring
• ISSN: 0019-0578; 1879-2022
• DOI: 10.1016/j.isatra.2023.09.007

The tool wear monitoring (TWM) system plays an increasingly important role to ensure high quality finishing and system safety in advanced CNC machining process. The pure data-based TWM approaches generally needs to develop complex machine learning models and require massive sensory data to learn the models to reach high monitoring accuracy, while the physics-based tool wear models are simple but hard to adapt to varied working conditions. In order to incorporate the benefits of both methods, a novel physics-informed Gaussian process model is developed to predict the tool wear. Different from the traditional approaches, three tool wear physical models are introduced to develop the physics-informed Gaussian process regression (PB-GPR) model. The wear model is applied to constrain the mean function of the Gaussian process, so that the PB-GPR is more in line with the actual tool wear. At the same time, the model can initiate small data training to meet limited tool wear labels in practice, and then update the model with new measurements. Multi-sensor signals are collected and multi-domain features are extracted for the model learning. The proposed approach is validated from high speed milling experiments. The results show a significant performance improvement including tool wear prediction accuracy and robustness in extrapolation compared to the conventional machine learning methods. •Propose a novel approach to explore the benefits both of physics and data methods.•Develop a physics-based Gaussian process regression model to predict the tool wear in a long term.•The model can be updated online and is effective for unexpected factors during machining process.•The model can provide high prediction accuracy and uncertainty estimation for tool wear monitoring.