Tool wear prediction based on K-means and Adaboost auto-encoder

Abstract A new tool wear prediction model is proposed to address the tool wear issue, aimed at monitoring tool wear based on specific task requirements and guiding tool replacement during actual cutting operations. In the data preprocessing phase, tool wear states are classified using unsupervised K-means clustering. The time, frequency, and time-frequency domain features are then labeled and fused using an autoencoder (AE) neural network applied to the original set of signal features from the tool. For tool wear prediction, an enhanced AE neural network leveraging AdaBoost is employed to establish the prediction model. The reconstruction error serves as the chosen loss function to assess the AE’s performance, taking into account data correlation and the inherent lossy nature of the AE. Experimental results from real machining data obtained from a CNC milling machine demonstrate that the proposed model achieves higher prediction accuracy while reducing data dimensions.