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Physics-informed inhomogeneous wear identification of end mills by online monitoring data 通过在线监测数据识别立铣刀非均质磨损的物理信息
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-17 DOI: 10.1016/j.jmapro.2024.11.020
Guochao Li , Shixian Xu , Ru Jiang , Yinfei Liu , Leyi Zhang , Hao Zheng , Li Sun , Yujing Sun
Online tool wear monitoring is an important component of intelligent milling. Integral end mill is one of the typical high-value cutting tools which has been widely used in aerospace, automobile, mold and other industries. Its cutting edge may produce inhomogeneous wear after suffering variable cutting depth experience. The existing methods are mainly focused on monitoring the maximum value of the tool wear, which cannot identify the inhomogeneous wear state and results in insufficient accuracy and practicality. Therefore, a physics-informed method is proposed to online identify inhomogeneous tool wear state. Firstly, a milling force mechanism model considering tool wear is established. The force model are expressed with matrix formulation so that the time-domain signals of the forces considering inhomogeneous wear can be easily simulated. Then, a total of 11 groups of single-factor simulation experiments are carried out to provide data support. Accordingly, 48 features for each group are extracted, including time-domain and frequency-domain features. By analyzing the Mean Absolute Percentage Error (MAPE) of the extracted features, it is found that the inhomogeneous wear has significant effect on the feature of skewness. Finally, the conclusion is verified by practical experiments through comparing the extracted features in homogeneous and inhomogeneous wear state. The study will provide theoretical and experimental supplement to the engineering application and improve the online wear monitoring accuracy of end mill.
刀具磨损在线监测是智能铣削的重要组成部分。整体立铣刀是典型的高价值切削刀具之一,已广泛应用于航空航天、汽车、模具等行业。其切削刃在经历不同的切削深度后会产生不均匀磨损。现有方法主要侧重于监测刀具磨损的最大值,无法识别非均质磨损状态,精度和实用性不足。因此,本文提出了一种物理信息方法来在线识别刀具的非均质磨损状态。首先,建立了考虑刀具磨损的铣削力机理模型。力模型采用矩阵表达方式,因此可以轻松模拟考虑非均质磨损的力的时域信号。然后,共进行了 11 组单因素模拟实验来提供数据支持。因此,每组都提取了 48 个特征,包括时域和频域特征。通过分析提取特征的平均绝对百分比误差(MAPE),发现非均匀磨损对偏度特征有显著影响。最后,通过比较在均质和非均质磨损状态下提取的特征,实际实验验证了上述结论。该研究将为工程应用提供理论和实验补充,提高立铣刀磨损在线监测精度。
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引用次数: 0
Role of metal surface amorphization on enhancing interfacial bonding in TC4-UHMWPE hybrid structure 金属表面非晶化对增强 TC4-UHMWPE 混合结构中界面结合的作用
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-17 DOI: 10.1016/j.jmapro.2024.11.010
Xin Zou , Ke Chen , Wei Zhou , Cong Chen , Zhenkun Cheng , Feifei Xie , Yafei Pei , Lingti Kong , Min Wang
Securing high-performance bonding between metals and non-polar polymers presents a significant challenge. Existing research mainly focused on the metal surface treatments to modify the morphology and chemical components, or introducing polar groups on the non-polar polymer via complicated modifications. This study introduced a novel interface engineering strategy involving metal surface amorphization, aimed at producing a high-performance hybrid structure of Ti6Al4V titanium alloy (TC4) and ultra-high molecular weight polyethylene (UHMWPE) for applications in artificial joint prostheses. The amorphous oxide layer grown on the TC4 surface significantly enhanced its chemical reactivity, facilitating interfacial chemical bonding between TC4 and in-situ functionalized UHMWPE during thermal-direct bonding. High-performance TC4-UHMWPE hybrid structures with lap-shear strength reaching 17.77 MPa (lap-shear force of 3732.4 N) were obtained using friction spot joining, underscoring the effectiveness of chemical bonding as the primary interfacial bonding mechanism. Meanwhile, both the chemical bonding type and the reaction mechanism were revealed with solid experimental evidence and density functional theory calculations for the first time. More importantly, the differences in bonding characteristics between amorphous and crystalline titanium oxides were revealed. This research not only deepens the understanding of interfacial bonding mechanisms and behaviors between different titanium oxides and polar groups but also provides a pioneering insight into manufacturing high-performance metal-polymer hybrid structures.
确保金属与非极性聚合物之间的高性能结合是一项重大挑战。现有的研究主要集中在通过金属表面处理来改变形态和化学成分,或通过复杂的改性在非极性聚合物上引入极性基团。本研究引入了一种涉及金属表面非晶化的新型界面工程策略,旨在生产一种高性能的 Ti6Al4V 钛合金(TC4)和超高分子量聚乙烯(UHMWPE)混合结构,应用于人工关节假体。在 TC4 表面生长的无定形氧化物层显著提高了其化学反应活性,在热直接粘合过程中促进了 TC4 与原位功能化超高分子量聚乙烯之间的界面化学键合。通过摩擦点连接,获得了搭接剪切强度达到 17.77 MPa(搭接剪切力为 3732.4 N)的高性能 TC4-UHMWPE 混合结构,证明了化学键作为主要界面键合机制的有效性。同时,实验证据和密度泛函理论计算首次揭示了化学键类型和反应机制。更重要的是,揭示了无定形钛氧化物与结晶钛氧化物键合特性的差异。这项研究不仅加深了人们对不同氧化钛和极性基团之间界面键合机理和行为的理解,而且为制造高性能金属聚合物杂化结构提供了开创性的见解。
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引用次数: 0
Die design parameters effect on dimensional conformity of PEM fuel cell bipolar plates in rotary forming of SS316L thin sheets 在 SS316L 薄板旋转成型过程中,模具设计参数对 PEM 燃料电池双极板尺寸一致性的影响
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-16 DOI: 10.1016/j.jmapro.2024.11.035
A. Asgari , M. Zeestraten , C.L. Walters
Rotary forming is a promising technique for high-volume, low-cost production of fuel cell components such as bipolar plates, but it needs to be better characterized for this application. In this paper, die design parameters in rotary forming of ultra-thin stainless steel 316 L sheets 100 μm thick are evaluated to explore how channels perpendicular and parallel to the rolling direction are affected by critical forming process parameters, namely depth of deformation, die corner radius, and friction coefficient. Channels are formed experimentally, and the results are used to verify the 2D and 3D simulations. The process is analysed in terms of die movement path and forming. Stress, strain, formed shape, and thickness are compared for the two main forming directions. Results showed that channels formed parallel to the rolling direction experience more plastic deformation and conform better to the prescribed geometry in terms of channel and flatness angles.
旋转成形是一种很有前途的技术,可用于大批量、低成本生产燃料电池组件(如双极板),但需要更好地确定其应用特性。本文评估了厚度为 100 μm 的超薄不锈钢 316 L 板旋转成形中的模具设计参数,以探讨垂直于和平行于轧制方向的沟道如何受到关键成形工艺参数(即变形深度、模具转角半径和摩擦系数)的影响。槽道是通过实验形成的,实验结果用于验证二维和三维模拟结果。从模具运动路径和成形方面分析了这一过程。比较了两个主要成型方向的应力、应变、成型形状和厚度。结果表明,平行于轧制方向形成的沟道经历了更大的塑性变形,在沟道角和平面角方面更符合规定的几何形状。
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引用次数: 0
Enhancing controllability in ultra-precision grinding of anisotropic rounded diamond tools through an in situ feature identification approach 通过现场特征识别方法提高各向异性圆形金刚石工具超精密磨削的可控性
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-15 DOI: 10.1016/j.jmapro.2024.11.018
Ruitao Zhang , Zhanfeng Wang , Zengqiang Li , Rongkai Tan , Junjie Zhang , Tao Sun
The conventional mechanical grinding approach for diamond tools, which is characterised by constant pressure and influenced by the pronounced anisotropy of single-crystal diamonds, faces challenges in precisely controlling the material removal rate on the tool’ flank face. This leads to uncertainties in both the processing quality and efficiency. To achieve ultra-precision manufacturing of rounded diamond cutting tools, this study meticulously explored the anisotropic characteristics of the material removal rate. An innovative in situ feature identification method is proposed to determine the process parameters for ultra-precision grinding processes with controlled removal rates. Experimental investigations scrutinized the intricate relationship between the model and the output current signal of the feed guide. Significantly, through the dynamic adjustment of the output current of the guide, the controllable grinding process achieved the successful production of ultra-precision tools, showing a remarkable profile error of <50 nm. These findings provide invaluable insights into ultra-precision machining, particularly in addressing the challenges posed by anisotropic diamond materials.
金刚石工具的传统机械磨削方法以恒定压力为特征,并受到单晶金刚石明显各向异性的影响,在精确控制工具侧面的材料去除率方面面临挑战。这导致了加工质量和效率的不确定性。为了实现圆角金刚石切削工具的超精密制造,本研究对材料去除率的各向异性特征进行了细致的探索。该研究提出了一种创新的原位特征识别方法,用于确定具有可控去除率的超精密磨削过程的工艺参数。实验研究仔细检查了模型与进给导轨输出电流信号之间的复杂关系。值得注意的是,通过动态调节导轨的输出电流,可控磨削工艺成功实现了超精密刀具的生产,其显著的轮廓误差为 50 nm。这些发现为超精密加工,尤其是应对各向异性金刚石材料带来的挑战提供了宝贵的见解。
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引用次数: 0
Surface modification of brittle polycrystalline materials by laser-assisted rolling 通过激光辅助轧制对脆性多晶材料进行表面改性
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-15 DOI: 10.1016/j.jmapro.2024.11.019
Kaiyuan You , Wei Wang , Bei Peng , Min Lai , Hai Jiang
This study proposes a novel surface modification method known as laser-assisted rolling, which aims to refine surface grains and enhance the machinability of brittle polycrystalline materials. This method establishes a foundation for achieving a crack-free and low-damage optical surface finish. Using binderless tungsten carbide as a case study, a systematic experimental investigation was carried out with a self-developed laser-assisted rolling system. The results show that the proposed method effectively refines surface grains by introducing dense defects. It also achieves a gradient grain size crystal structure and a residual compressive stress state without causing surface cracks. The formation and evolution mechanisms of the modified layer were comprehensively studied. Moreover, this novel method is expected to offer theoretical guidance for the surface modification of other brittle polycrystalline materials.
本研究提出了一种新的表面改性方法--激光辅助轧制,旨在细化脆性多晶材料的表面晶粒并提高其可加工性。这种方法为实现无裂纹、低损伤的光学表面处理奠定了基础。以无粘结剂碳化钨为例,利用自主研发的激光辅助轧制系统进行了系统的实验研究。结果表明,所提出的方法通过引入致密缺陷有效地细化了表面晶粒。它还实现了梯度晶粒大小的晶体结构和残余压应力状态,且不会造成表面裂纹。对改性层的形成和演化机制进行了全面研究。此外,这种新方法有望为其他脆性多晶材料的表面改性提供理论指导。
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引用次数: 0
Additive manufacturing of AISI M2 tool steel by binder jetting (BJ): Investigation of microstructural and mechanical properties 通过粘结剂喷射 (BJ) 对 AISI M2 工具钢进行增材制造:微观结构和机械性能研究
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-15 DOI: 10.1016/j.jmapro.2024.11.008
Amit Choudhari , James Elder , Manoj Mugale , Sanoj Karki , Venkata Bhuvaneswari Vukkum , Rajeev Kumar Gupta , Tushar Borkar
The presented research demonstrates for the first time the successful processing of AISI M2 tool steel by binder jetting, a promising additive manufacturing technique capable of producing complex shapes with minimal residual stresses and isotropic properties. The optimal printing parameters were explored by varying processing parameters such as the binder saturation (45 %–105 %), binder set time (0 to 10 s), targeted bed temperature (50–60 °C), oscillator (2600–2750 rpm), recoater (20–28 mm/s), and roller speeds (200–300 rpm). Microstructural characterization and evaluation of mechanical properties of binder jetted parts were performed using x-ray diffraction (XRD), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS) to study their chemical composition, powder morphology, microstructure, carbide morphologies, relative density, hardness, compressive strength, and ductility. Two powder sizes (5 and 10 μm) were used, and sintering was performed at varying temperatures (1270, 1280, and 1300 °C) and durations (60 and 120 min), followed by a furnace, air, and water cooling. An optimum hardness of ∼970 HV was obtained when parts were sintered at 1270 °C for 60 min, followed by water quenching. Impressive compressive strength of ∼ 3580 MPa was observed in the sample sintered at 1280 °C for 60 min duration, followed by air cooling. Furnace-cooled parts showed the highest density of ∼95 %, whereas the relative density of air- and water-cooled parts varied between ∼91 to 93.50 %, respectively. The microstructure of sintered samples revealed the formation of M6C stable carbide, M2C metastable carbide, MC as a secondary carbide, and α-Fe matrix, which contributed to the observed increase in mechanical properties.
该研究首次展示了通过粘合剂喷射成功加工 AISI M2 工具钢的过程,这是一种很有前途的增材制造技术,能够生产出具有最小残余应力和各向同性的复杂形状。通过改变加工参数,如粘合剂饱和度(45%-105%)、粘合剂凝固时间(0-10 秒)、目标床层温度(50-60 °C)、振荡器(2600-2750 rpm)、再涂器(20-28 mm/s)和辊筒速度(200-300 rpm),探索了最佳打印参数。使用 X 射线衍射 (XRD)、扫描电子显微镜 (SEM) 和能量色散光谱 (EDS) 对粘合剂喷射部件进行了微观结构表征和机械性能评估,以研究其化学成分、粉末形态、微观结构、碳化物形态、相对密度、硬度、抗压强度和延展性。使用了两种尺寸(5 和 10 μm)的粉末,并在不同温度(1270、1280 和 1300 ℃)和持续时间(60 和 120 分钟)下进行烧结,然后进行炉冷、空冷和水冷。在 1270 °C 下烧结 60 分钟,然后进行水淬,零件的最佳硬度为 970 HV。在 1280 ℃ 下烧结 60 分钟,然后空冷的样品抗压强度达到 3580 兆帕。窑炉冷却部分的密度最高,达到 95%,而空气冷却和水冷却部分的相对密度分别为 91% 至 93.50%。烧结样品的微观结构显示形成了 M6C 稳定碳化物、M2C 可转移碳化物、作为次生碳化物的 MC 和 α-Fe 基体,这有助于观察到的机械性能的提高。
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引用次数: 0
Material deformation mechanism of polycrystalline tin in nanometric cutting 纳米切割中多晶锡的材料变形机理
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-15 DOI: 10.1016/j.jmapro.2024.11.021
Zhifu Xue , Min Lai , Feifei Xu , Fengzhou Fang
The surface generation and subsurface deformation mechanisms of polycrystalline tin in nanometric cutting are investigated using molecular dynamics. Subsurface deformations such as amorphization, phase transformation, grain boundary migration, and grain rotation during machining are observed. The distribution of hydrostatic stress and the evolution of the crystal structure are analyzed to determine the causes of cutting force fluctuations. The effects of undeformed chip thickness and cutting speed on material removal and subsurface deformation are also examined. Results show that the propagation of deformation is suppressed by the grain boundaries, and the grain boundary steps on the machined surfaces are expanded by deformation recovery. In addition, the removal behavior of polycrystalline tin is remarkably affected by the grain size and crystal orientation.
利用分子动力学研究了纳米切削中多晶锡的表面生成和表层下变形机制。观察了加工过程中的非晶化、相变、晶界迁移和晶粒旋转等次表层变形。分析了静水压力的分布和晶体结构的演变,以确定切削力波动的原因。此外,还研究了未变形切屑厚度和切削速度对材料去除和表面下变形的影响。结果表明,变形的传播受到晶界的抑制,加工表面上的晶界台阶因变形恢复而扩大。此外,多晶锡的移除行为明显受到晶粒尺寸和晶体取向的影响。
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引用次数: 0
A parametric evaluation model of abrasive interaction for predicting tooth rough surface in spiral bevel gear grinding 用于预测弧齿锥齿轮磨削中齿面粗糙度的磨料相互作用参数评估模型
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-15 DOI: 10.1016/j.jmapro.2024.11.012
Weihua Zhou , Jinyuan Tang , Kaibin Rong , Zhuan Li , Wen Shao
The grinding of complex surface parts, such as spiral bevel gears (SBGs), involves intricate machine-tool settings and localized machining conditions. These factors contribute to the nonuniformity of the macro envelope and the complex cumulative behavior of grits, thereby increasing the challenge of predicting surface roughness. This paper proposes a novel parametric model that directly relates local envelope parameters influenced by machine-tool settings to abrasive interaction features. Four inclination angles are defined to describe the irregular abrasive posture and the coupled kinematics of generating grinding. Additionally, the calculation strategy of undeformed chip thickness with discrete grinding groove overlap is introduced. Based on the parametric model and the macro wheel-tooth geometry, we further simulate the micro-tooth surface and validate the simulation through experiments. The results indicate that the roughness of the convex surface of the pinion is lower compared to the concave surface. This discrepancy arises from variations in the equivalent contact radius and the inclined abrasive posture. Increasing the speed ratio between the tool rotation and the generating effectively reduces the roughness distribution discrepancy. This work provides a valuable guidance for the manufacturing of high-performance SBGs and quantifies the micro-topography evolution for any abrasive geometry, kinematics, and posture.
磨削螺旋锥齿轮 (SBG) 等复杂表面零件涉及复杂的机床设置和局部加工条件。这些因素导致了宏观包络的不均匀性和磨粒复杂的累积行为,从而增加了预测表面粗糙度的难度。本文提出了一种新颖的参数模型,将受机床工具设置影响的局部包络参数与磨料相互作用特征直接联系起来。本文定义了四个倾角来描述不规则磨料姿态和产生磨削的耦合运动学。此外,还介绍了具有离散磨槽重叠的未变形切屑厚度的计算策略。基于参数模型和宏观轮齿几何形状,我们进一步模拟了微观轮齿表面,并通过实验验证了模拟结果。结果表明,小齿轮凸面的粗糙度低于凹面。这种差异源于等效接触半径和倾斜磨料姿态的变化。提高刀具旋转和生成之间的速度比可有效减少粗糙度分布差异。这项工作为制造高性能 SBG 提供了宝贵的指导,并量化了任何磨料几何形状、运动学和姿态下的微观形貌演变。
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引用次数: 0
Molecular dynamics simulation for temperature assisted machining of a polycrystalline γ-TiAl alloy 多晶γ-TiAl 合金温度辅助加工的分子动力学模拟
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-15 DOI: 10.1016/j.jmapro.2024.11.016
Zehai Ren , Ruicheng Feng , Baocheng Zhou , Hui Cao , Haiyan Li , Wenle Yang , Chunli Lei
Temperature-assisted machining is an effective method for improving the machining quality of difficult-to-machine materials. A nano-cutting model was developed using molecular dynamics simulation to reveal the effect of temperature on the cutting performance of a polycrystalline γ-TiAl alloy. The effects of temperature on cutting force, tool wear, plastic deformation, microstructure evolution, subsurface damage, and surface formation process were analyzed based on the levels of thermal activation energy and dislocation theory. Results indicated that the machining quality was a combination of the softening of temperature fields and hardening of stress fields. If the assisting temperature was too high or low, the temperature fields and the stress fields, one of which dominates, the improvement in machining quality was poor. When the assisting temperature was approximately 500 K, the temperature fields and the stress fields matched, plastic deformation, tool wear, and subsurface damage were small, and the machined surface quality was relatively optimal. Recovery and recrystallization lead to microstructural evolution; higher temperatures increased the degree of migration of grain boundaries, and the removal of material from the shear mode gradually transitioned to the removal mode for the coexistence of shear and extrusion. This study can deepen our understanding of the temperature-assisted machining characteristics of the alloy and provide a theoretical basis for regulating the performance of the alloy and improving the machining quality at a macro scale.
温度辅助加工是提高难加工材料加工质量的有效方法。为了揭示温度对多晶γ-TiAl合金切削性能的影响,我们利用分子动力学模拟建立了一个纳米切削模型。基于热活化能和位错理论,分析了温度对切削力、刀具磨损、塑性变形、微观结构演变、表面下损伤和表面形成过程的影响。结果表明,加工质量是温度场软化和应力场硬化的综合结果。如果辅助温度过高或过低,温度场和应力场中的一个占主导地位,则加工质量的改善效果不佳。当辅助温度约为 500 K 时,温度场和应力场相匹配,塑性变形、刀具磨损和表面下损伤较小,加工表面质量相对最佳。恢复和再结晶导致了微观结构的演变;较高的温度增加了晶界的迁移程度,材料的去除从剪切模式逐渐过渡到剪切和挤压共存的去除模式。该研究可加深对合金温度辅助加工特性的理解,为宏观调控合金性能、提高加工质量提供理论依据。
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引用次数: 0
An on-machine tool wear area identification method based on image augmentation and advanced segmentation 基于图像增强和高级分割的机上刀具磨损区域识别方法
IF 6.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING Pub Date : 2024-11-15 DOI: 10.1016/j.jmapro.2024.10.085
Honghuan Chen , Cong Cheng , Jiangkun Hong , Mengqin Huang , Yaguang Kong , Xiaoqing Zheng
In industrial manufacturing, tool wear monitoring (TWM) is essential for ensuring high-quality machining, operational efficiency, cost-effectiveness, and safety. However, due to the complexities of on-machine imaging and the constraints of direct measurement techniques, TWM methods face challenges such as unclear boundaries, class imbalance between wear and unworn area, and image diversity. This paper proposes a novel two-step approach for identifying tool wear areas. Firstly, DeepLabV3+ with Focal Loss is utilized to identify the Region of Interest (ROI) of the tool. Secondly, the method employs Intuitionistic Fuzzy C-Means Clustering (IFCM) for detailed segmentation of the wear area. This integration effectively addresses challenges arising from uneven illumination that blur image boundaries and the class imbalance between images with tool wear and those without. To enhance image diversity and quality, we utilize Denoising Diffusion Probabilistic Models (DDPM) for image augmentation, significantly enriching the training dataset. The proposed approach achieves a Mean Pixel Accuracy (MPA) of 95.32% and a Mean Intersection over Union (MIoU) of 93.67%, which marks a substantial improvement over existing TWM models. This progress not only provides a more reliable and efficient tool wear monitoring solution but also sets a new standard for precision in industrial machining processes.
在工业制造领域,刀具磨损监测(TWM)对于确保高质量加工、运行效率、成本效益和安全性至关重要。然而,由于机上成像的复杂性和直接测量技术的限制,TWM 方法面临着边界不清晰、磨损区域和未磨损区域之间等级不平衡以及图像多样性等挑战。本文提出了一种分两步识别刀具磨损区域的新方法。首先,利用带有 Focal Loss 的 DeepLabV3+ 来识别刀具的感兴趣区域(ROI)。其次,该方法采用直觉模糊 C-Means 聚类(IFCM)对磨损区域进行详细分割。这种整合有效地解决了因光照不均而导致的图像边界模糊以及有工具磨损和无工具磨损的图像之间的类别不平衡所带来的挑战。为了提高图像的多样性和质量,我们利用去噪扩散概率模型(DDPM)进行图像增强,极大地丰富了训练数据集。所提出的方法实现了 95.32% 的平均像素准确率 (MPA),以及 93.67% 的平均联合交叉率 (MIoU),与现有的 TWM 模型相比有了大幅提高。这一进步不仅提供了更可靠、更高效的刀具磨损监测解决方案,还为工业加工过程的精度设定了新标准。
{"title":"An on-machine tool wear area identification method based on image augmentation and advanced segmentation","authors":"Honghuan Chen ,&nbsp;Cong Cheng ,&nbsp;Jiangkun Hong ,&nbsp;Mengqin Huang ,&nbsp;Yaguang Kong ,&nbsp;Xiaoqing Zheng","doi":"10.1016/j.jmapro.2024.10.085","DOIUrl":"10.1016/j.jmapro.2024.10.085","url":null,"abstract":"<div><div>In industrial manufacturing, tool wear monitoring (TWM) is essential for ensuring high-quality machining, operational efficiency, cost-effectiveness, and safety. However, due to the complexities of on-machine imaging and the constraints of direct measurement techniques, TWM methods face challenges such as unclear boundaries, class imbalance between wear and unworn area, and image diversity. This paper proposes a novel two-step approach for identifying tool wear areas. Firstly, DeepLabV3<span><math><msup><mrow></mrow><mrow><mo>+</mo></mrow></msup></math></span> with Focal Loss is utilized to identify the Region of Interest (ROI) of the tool. Secondly, the method employs Intuitionistic Fuzzy C-Means Clustering (IFCM) for detailed segmentation of the wear area. This integration effectively addresses challenges arising from uneven illumination that blur image boundaries and the class imbalance between images with tool wear and those without. To enhance image diversity and quality, we utilize Denoising Diffusion Probabilistic Models (DDPM) for image augmentation, significantly enriching the training dataset. The proposed approach achieves a Mean Pixel Accuracy (MPA) of 95.32% and a Mean Intersection over Union (MIoU) of 93.67%, which marks a substantial improvement over existing TWM models. This progress not only provides a more reliable and efficient tool wear monitoring solution but also sets a new standard for precision in industrial machining processes.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"132 ","pages":"Pages 558-569"},"PeriodicalIF":6.1,"publicationDate":"2024-11-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142657380","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
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Journal of Manufacturing Processes
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