A SURVEY ON MANCHINING MONITORING SYSTEMS

BASED ON ARTIFICIAL INTELLIGENCE PROCESS

MODELS
UNDER THE GUIDENCE OF
MR.S.SATHISH
ASSISSTANT PROFESSOR

PRESENTED BY
S.PREMKUMAR
ME – MANUFACTURING ENGINEERING
SRI RAMAKRISHNA ENGINEERING COLLEGE
COIMBATORE.
OBJECTIVE:

• To identify the six key issues in conditional monitoring.

• To monitor the six key issues AI system is used in this paper.

PROBLEM DEFINITION:

• Present monitoring system are based on man power but it is not

accurate and faster. It also reduces the production rate.

• To avoid this inaccuracy and low production rate the condition

monitoring are carried out, with the help of AI system. Which
could be better and faster than the traditional system.
SCOPE OF THE PROJECT:

• Monitoring part accuracy

• Surface roughness
• Geometric quality

• Cutting-tool condition
• Tool wear
• Tool breakage
Six key issues involved in the development of
intelligent machining systems:
• The different sensor systems applied to monitor machining
processes,
• The most effective signal processing techniques,
• The most frequent sensory features applied in modelling
machining processes,
• The sensory feature selection and extraction methods
for using relevant sensory information,
• The design of experiments required to model a machining
operation with the minimum amount of experimental
data,
• The main characteristics of several artificial intelligence
techniques to facilitate their application/selection.
METHODOLOGY:
A generic methodology for developing an intelligent
monitoring system for machining is composed of six key issues:

 Sensors
 Signal processing
 Feature generation
 Feature selection/extraction
 AI technique
 Design of experiments
SENSORS USED:

Four sensors have been widely applied to monitor machining

systems,

 Dynamometers
 Accelerometers
 AE sensors
 Current sensors
Fig. 2 Frequency of sensor usage related to machining monitoring
systems
Where,
RMS - Root mean square
N - Sampled sensor data
n - Number of sensors used in the system
xi - Sample values
SIGNAL PROCESSING:

• An appropriate signal processing strategy is mandatory before

selecting/extracting sensory features due to the high levels of
mechanical, electrical and acoustic noises in industrial
environments.

• In general, intelligent monitoring systems for machining apply

the signal processing scheme shown in the below Fig.3.
FEATURE GENERATION:

 The fourth step consists of a feature generation module, which

transforms the digital signal into several signal features called
descriptors or features.

 Different methods have been applied for feature generation in

the time, frequency and wavelet domains.
FEATURE SELECTION/EXTRACTION:

• After generating the features, one can obtain many different

descriptors from different sensor signals, and so, a feature
selection or extraction procedure is required.

• In general, most of the research studies published in

machining monitoring systems usually present a direct feature
selection, mainly involving root mean squares features mean
values or harmonic signal values.
AI TECHNIQUE:

 Conducting a correct DoE may make it possible to fit a

regression model relatively well using cutting parameters as
regressors.

 The main AI techniques applied for modelling and monitoring

machining systems are artificial neural networks (ANN),
expert systems called fuzzy logic systems and the AI
technique that results from the hybridisation of these two
techniques, called neuro-fuzzy inference Systems.
DESIGN OF EXPERIMENTS:
• While machining experimentation is costly and
timeconsuming, it is important to carry out effective
experiments with few runs in order to find out the most
relevant factors for a certain machining performance variable.

• In the past, various methods have been used to quantify the

impact of machining parameters (cutting speed, depth of cut,
feed, etc.) and process variables (vibrations, tool wear,
temperatures, etc.) on part quality and cutting-tool state.
In general, four methodologies are applied in DoE:
 Full factorial designs,

 Fractional factorial designs,

 Taguchi’s orthogonal arrays, and

 Response surface designs.

• A DoE with every possible combination of all the input factors

is called a full factorial design.

• Taguchi’s orthogonal arrays are similar to fractional factorial

designs, but they apply new concepts to parameter design and

tolerance design.
• A response surface design is another DoE method which

investigates how important factors affect the response of an

experiment.
PERIODIC MODEL VERIFICATION:
• A machining monitoring system should be periodically
verified in order to detect changes in the machining
performance.

• Due to changes in machining operation, the machining model

learnt by AI techniques may have to be re-trained in order to
be adapted to a new machining process.

• Two statistical tests have to be conducted to infer whether the

present machining process conditions are statistically
equivalent to the previous ones where the monitoring system
was implemented, i.e. the equal variance test and the two-
sample “ t “ test.
• The results of both tests indicate whether, statistically
speaking, there is any change in the machining process
behaviour, and then whether the monitoring machining system
can still be applied or it requires a re-training process.

The null and alternative hypotheses for the equal variance test
are defined as follows:
 n1–1 and n2-1 DOFs in the numerator and denominator,
respectively,
where n1 and n2 are the sample size.

The variables s12 and s22 define the variances of each sample.
hypothesis, which means the two samples have the same
variance, is rejected if:

where f(α/2,n1−1,n2−1) is the value of the F distribution with

n1 − 1 and n2− 1 DOFs at a significance level of α.
The null and alternative hypotheses for the twosample
“t” test are defined as:

H0 : μ1 = μ2
Ha : μ1 = μ2

and the two-sample “t” test statistic is:

 where Y1 and Y2 are the sample means. The null hypothesis that
the two means are equal is rejected if:

where T > t(α/2,v) is the value of the “t” distribution with v DOFs
at a significance level of α, where:
The paper has reviewed:

1. The different sensor systems applied to the monitoring of

machining processes,
2. The most effective signal processing techniques,
3. The frequent sensory features applied in modelling
machining processes,
4. The sensory feature extraction methods for using the relevant
sensory information,
5. The DoE required to model a machining operation with
minimum experimental data
6. The main characteristics of several AI techniques to facilitate
their application/selection.
CONCLUSION:

• Many machining monitoring systems based on AI process

models have been developed in the past for optimising,
predicting or controlling machining processes.
• All research works present different methodologies without
showing clear guidelines or key issues for the development of
intelligent machining systems.
• In order to overcome the lack of a global view on how to
develop machining monitoring systems based on AI models,
this paper has presented a generic methodology which reviews
the main parts of a machining monitoring system and includes
the most relevant aspects from previous machining monitoring
systems presented in the literature.
THAKN YOU