A data-driven approach to RUL prediction of tools

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A data-driven approach to RUL prediction of tools

Wei Li , Liang-Chi Zhang , Chu-Han Wu , Yan Wang , Zhen-Xiang Cui , Chao Niu

Advances in Manufacturing ›› 2024, Vol. 12 ›› Issue (1) : 6 -18.

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Advances in Manufacturing ›› 2024, Vol. 12 ›› Issue (1) : 6 -18. DOI: 10.1007/s40436-023-00464-y

Article

A data-driven approach to RUL prediction of tools

Wei Li ¹^,⁵
, Liang-Chi Zhang ²^,³^,⁴^,^b
, Chu-Han Wu ⁵
, Yan Wang ⁵
, Zhen-Xiang Cui ⁶
, Chao Niu ⁶

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¹ Department of Mechanical Engineering, University College London, WC1E 7JE, London, UK

² Shenzhen Key Laboratory of Cross-Scale Manufacturing Mechanics, Southern University of Science and Technology, 518055, Shenzhen, Guangdong, People’s Republic of China

³ SUSTech Institute for Manufacturing Innovation, Southern University of Science and Technology, 518055, Shenzhen, Guangdong, People’s Republic of China

⁴ Department of Mechanics and Aerospace Engineering, Southern University of Science and Technology, 518055, Shenzhen, Guangdong, People’s Republic of China

⁵ School of Mechanical and Manufacturing Engineering, The University of New South Wales, 2052, Kensington, NSW, Australia

⁶ Baoshan Iron & Steel Co., Ltd., 200941, Shanghai, People’s Republic of China

^b zhanglc@sustech.edu.cn

Wei Li is a research fellow in the Department of Mechanical Engineering at University College London. He received his Ph.D. from the University of New South Wales in 2022. His current research fields include deep learning, metal forming, image processing and additive manufacturing.

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Liang-Chi Zhang is an academician/chair professor at Southern University of Science and Technology. His research interests include precision manufacturing, bio-manufacturing, nanotechnology, characterisation of advanced materials, tribology, solid mechanics, computational mechanics.

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Chu-Han Wu is a research fellow in the school of Mechanical and Manufacturing Engineering at the University of New South Wales Australia. He received his Ph.D. from the University of New South Wales in 2016. His current research fields include contact mechanics, lubrication theory, numerical modelling and metal forming.

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Yan Wang is a PhD candidate at the School of Mechanical and Manufacturing Engineering, University of New South Wales, Australia. Her research interests include wear testing, lubricated wear and wear mechanism, with a focus on surface integrity of magnesium alloys subjected to sliding and rolling.

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Zhen-Xiang Cui is a researcher at the Research Institute of Baoshan Iron & Steel Co., Ltd. His research interests include the forming of advanced high strength steel, the galling & wear of tools and the galling characteristics of steel plate.

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Chao Niu is a researcher of Baoshan Iron and Steel Co., Ltd., engaged in the research of cold stamping forming technology of high strength steels. He has a deep research on mechanical behaviour characterization, formability evaluation and analysis, spring back prediction, etc.

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Abstract

An effective and reliable prediction of the remaining useful life (RUL) of a tool is important to a metal forming process because it can significantly reduce unexpected maintenance, avoid machine shutdowns and increase system stability. This study proposes a new data-driven approach to the RUL prediction for metal forming processes under multiple contact sliding conditions. The data-driven approach took advantage of bidirectional long short-term memory (BLSTM) and convolutional neural networks (CNN). A pre-trained lightweight CNN-based network, WearNet, was re-trained to classify the wear states of workpiece surfaces with a high accuracy, then the classification results were passed into a BLSTM-based regression model as inputs for RUL estimation. The experimental results demonstrated that this approach was able to predict the RUL values with a small error (below 5%) and a low root mean square error (RMSE) (around 1.5), which was more superior and robust than the other state-of-the-art methods.

Keywords

Remaining useful life (RUL) / Bidirectional long short-term memory (BLSTM) / Data-driven approach / Metal forming

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Wei Li, Liang-Chi Zhang, Chu-Han Wu, Yan Wang, Zhen-Xiang Cui, Chao Niu. A data-driven approach to RUL prediction of tools. Advances in Manufacturing, 2024, 12(1): 6-18 DOI:10.1007/s40436-023-00464-y

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Funding

Baosteel-Australia Joint Research and Development Centre http://dx.doi.org/10.13039/501100020692(BA17001)

ARC Hub for Computational Particle Technology(IH140100035)

Chinese Guangdong Specific Discipline Project(2020ZDZX2006)

Shenzhen Key Laboratory Project of Cross-scale Manufacturing Mechanics(ZDSYS20200810171201007)

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