An online monitoring method of milling cutter wear condition driven by digital twin

Real-time online tracking of tool wear is an indispensable element in automated machining, and tool wear directly impacts the processing quality of workpieces and overall productivity. For the milling tool wear state is difficult to real-time visualization monitoring and individual tool wear prediction model deviation is large and is not stable and so on, a digital twin-driven ensemble learning milling tool wear online monitoring novel method is proposed in this paper. Firstly, a digital twin-based milling tool wear monitoring system is built and the system model structure is clarified. Secondly, through the digital twin (DT) data multi-level processing system to optimize the signal characteristic data, combined with the ensemble learning model to predict the milling cutter wear status and wear values in real-time, the two will be verified with each other to enhance the prediction accuracy of the system. Finally, taking the milling wear experiment as an application case, the outcomes display that the predictive precision of the monitoring method is more than 96% and the prediction time is below 0.1 s, which verifies the effectiveness of the presented method, and provides a novel idea and a new approach for real-time on-line tracking of milling cutter wear in intelligent manufacturing process.