基于多源信号融合的刀具状态监测研究进展
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1.西安交通大学仪器科学与技术学院西安710049; 2.西安交通大学精密微纳制造技术全国重点实验室 西安710049; 3.西安交通大学微纳制造与测试技术国际合作联合实验室西安710049; 4.西安交通大学机械工程学院西安710049

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TH117.1

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Research progress on tool condition monitoring based on multi-source signal fusion
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1.School of Instrument Science and Technology, Xi′an Jiaotong University,Xi′an 710049, China; 2.State Key Laboratory for Manufacturing Systems Engineering, Xi′an Jiaotong University,Xi′an 710049, China; 3.International Joint Laboratory for Micro/Nano Manufacturing and Measurement Technologies, Xi′an Jiaotong University, Xi′an 710049, China; 4.School of Mechanical Engineering, Xi′an Jiaotong University,Xi′an 710049, China

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    摘要:

    刀具状态监测是保障数控机床加工质量、提升生产效率及延长设备寿命的关键技术。刀具作为加工系统中的关键执行部件,其磨损、崩刃等失效形式直接影响加工精度与系统可靠性。受切削参数变化、工况波动及环境噪声等因素影响,刀具退化过程具有连续、不可逆和不确定等特征,单一传感信号在信息完整性与抗干扰能力方面存在明显不足。多源信号融合技术通过整合切削力、振动、声发射、电流、功率等多传感器信号的优势,为实现高精度、高鲁棒性的刀具在线状态监测提供了有效途径。围绕多源信号融合技术在刀具状态监测中的应用,对相关理论框架与研究进展进行了系统综述。分析了切削力、振动、声发射等常用传感器类型及其集成方式,对比了不同传感器在信号获取精度、抗干扰能力及响应特性等方面的性能差异。随后,重点探讨了数据级、特征级与决策级融合策略,涵盖滤波算法、机器学习模型及不确定性推理方法等关键技术,系统阐述了各类方法的适用场景及实现效果。结合刀具破损识别、磨损评估与剩余寿命预测等典型应用,揭示了多源信号融合在提升监测精度与可靠性方面的优势。最后,总结了当前研究挑战并提出未来发展方向,为刀具全生命周期监测提供理论依据与工程参考。

    Abstract:

    Tool condition monitoring (TCM) is a key technology for ensuring machining quality, improving production efficiency, and extending the service life of computer numerical control (CNC) machine tools. As a core component of the machining system, the cutting tool is subject to failure modes such as wear and chipping, which directly affect machining accuracy and system reliability. Influenced by variations in cutting parameters, fluctuations in operating conditions, and environmental noise, the tool wear process exhibits continuous, irreversible, and uncertain characteristics, resulting in evident limitations of single-sensor signals in terms of information completeness and anti-interference capability. By integrating the complementary advantages of multi-sensor signals such as cutting force, vibration, acoustic emission, current, and power, multi-source signal fusion provides an effective approach for achieving highly accurate and robust online tool condition monitoring. Focusing on the application of multi-source signal fusion in TCM, this work presents a systematic review of relevant theoretical frameworks and research progress. Common sensor types, including cutting force, vibration, and acoustic emission sensors, as well as their integration methods, are analyzed, and the performance differences among various sensors in terms of signal acquisition accuracy, anti-interference capability, and response characteristics are compared. Subsequently, data-level, feature-level, and decision-level fusion strategies are discussed, including filtering algorithms, machine learning models, and uncertainty reasoning methods. Typical applications such as tool breakage detection, wear monitoring, and remaining useful life prediction are reviewed to reveal the advantages of multi-source signal fusion in improving monitoring accuracy and system reliability. Finally, current challenges and future directions are summarized, providing theoretical and practical references for tool lifecycle monitoring.

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王松,王琛英,张雅馨,钟倩倩,蒋庄德.基于多源信号融合的刀具状态监测研究进展[J].仪器仪表学报,2026,47(1):47-63

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  • 在线发布日期: 2026-03-30
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