Multi-Step-Ahead Tool State Monitoring Using Clustering Feature-Based Recurrent Fuzzy Neural Networks

Reliable and precise multi-step-ahead tool wear state prediction is significant to modern industries for maintaining part quality and reducing cost. This study proposes a Clustering Feature-based Recurrent Fuzzy Neural Network (CFRFNN) for tool wear state monitoring and remaining useful life (RUL) prediction based on K-means Clustering, Recurrent Fuzzy Neural Network (RFNN) and Genetic Algorithm (GA). K-means Clustering method is utilized to realize tool wear state definition and input signal division, which reduces the dependence on the prior knowledge of tool wear degree and improves the prediction accuracy. Then, an enhanced RFNN model is designed and applied on the clustered features to predict tool wear state. The optimized GA technique is helpful for adaptive optimization of model parameters, which significantly improves convergence rate and prediction accuracy. The experiments on tool state prediction are performed to validate superiority of CFRFNN, and the results demonstrate that the proposed network could reasonably configure the complex non-stationary tool wear process and have high prediction accuracy of tool wear state.