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On-line part deformation prediction based on deep learning

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Abstract

Deformation prediction is the basis of deformation control in manufacturing process planning. This paper presents an on-line part deformation prediction method using a deep learning model during numerical control machining process, which is different from traditional methods based on finite element simulation of stress release prior to the actual machining process. A fourth-order tensor model is proposed to represent the continuous part geometric information, process information, and monitoring information, which is used as the input to the deep learning model. A deep learning framework with a conventional neural network and a recurrent neural network has been constructed and trained by monitored deformation data and process information associated with interim part geometric information. The proposed method can be generalised for different parts with certain similarities and has the potential to provide a reference for an adaptive machining control strategy for reducing part deformation. The proposed method was validated by actual machining experiments, and the results show that the prediction accuracy has been improved compared with existing methods. Furthermore, this paper shifts the difficult problem of residual stress measurement and off-line deformation prediction to the solution of on-line deformation prediction based on deformation monitoring data.

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Acknowledgements

The reported research was funded by the National Natural Science Foundation of China (Ref. 51775278), the National Natural Science Foundation of China—Chinese Aerospace Science and Technology Corporation on Advanced Manufacturing (Ref. U1537209), and the Jiangsu Province Outstanding Youth Fund (Ref. BK20140036).

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Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, 29 Yudao Street, Nanjing, 210016, China

    Zhiwei Zhao

  2. National Key Laboratory of Science and Technology on Helicopter Transmission, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Yingguang Li & Changqing Liu

  3. School of Engineering, University of Greenwich, Chatham Maritime, Kent, ME4 4TB, UK

    James Gao

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  1. Zhiwei Zhao
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  2. Yingguang Li
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  3. Changqing Liu
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  4. James Gao
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Correspondence to Yingguang Li.

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Zhao, Z., Li, Y., Liu, C. et al. On-line part deformation prediction based on deep learning. J Intell Manuf 31, 561–574 (2020). https://doi.org/10.1007/s10845-019-01465-0

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