Real-time reliability analysis of micro-milling processes considering the effects of tool wear

The development of micro-milling technology has promoted the high-precision machining of complex and small-size parts in modern manufacturing. Accurate cutting force control and reasonable machining parameters selection are conducive to the sustainable machining of micro-milling. In this work, a micro-milling mechanical model considering the change of tool wear, tool runout, and chip separation status with cutting time is proposed with the improved Gated Recurrent Unit with Multi-objective Dandelion Optimizer and mathematical modeling. The modeling accuracy is verified by experiments on Al6061. Combined with the established framework and the practical physical information, the posterior distribution of process parameters is inverted using the Bayesian updating method. Finally, the reliability calculation of machining system parameters is efficiently realized utilizing the posterior information and the High-dimensional Model Representation with the Stochastic configuration network method. The influence degree of the change of cutting parameters on the extreme value of micro-milling force is evaluated. The research results can provide analytical methods and theoretical guidance to ensure safe processing.