Prediction of Flank Wear during Turning of EN8 Steel with Cutting Force Signals Using a Deep Learning Approach

Abstract

Currently, manufacturing industries focus on intelligent manufacturing. Prediction and monitoring of tool wear are essential in any material removal process, and implementation of a tool condition monitoring system (TCMS) is necessary. This work presents the flank wear prediction during the hard turning of EN8 steel using the deep learning (DL) algorithm. The turning operation is conducted with three levels of selected parameters. CNMG 120408 grade, TiN-coated cemented carbide tool is used for turning. Cutting force and flank wear are assessed under dry-cutting conditions. DL algorithms such as adaptive neuro-fuzzy inference system (ANFIS) and convolutional auto encoder (CAE) are used to predict the flank wear of the single-point cutting tool. The DL model is developed with turning parameters and cutting force to predict flank wear. The different ANFIS and CAE models are employed to develop the prediction model. Grid-based ANFIS structure with Gauss membership function performed better than ANFIS models. The ANFIS model’s average testing error of 0.0074011 mm and prediction accuracy of 99.81% are achieved.