With the trend of lightweight in the field of intelligent electric vehicles and 3C, the demand for high precision machining of aluminum alloy parts is growing. And tool condition monitoring (TCM) is very important for quality control of parts, so intelligent high-accuracy wear prediction of aluminum alloy high precision machining tools has great industrial application value at present and in the future. This paper presents a novel TCM model (Conv-PhyFormer) of Transformer with physics informed. The model has excellent ability to capture short-term and long-term dependencies from nonlinear cutting time series data when there are few training samples. The embedded hard physical constraint and soft physical constraint in the model make the model partially interpretable. Soft physical constraint in the form of one-dimensional causal convolution can help the proposed model better learn the local context. Hard physical constraint in the form of the mathematical equation representing cutting physical knowledge are embedded, thus the model does not need to learn this knowledge from time series data from scratch. A large number of analysis results of aluminum alloy machining experimental data show that the proposed Conv-PhyFormer has significantly superior prediction accuracy and robustness compared with the current three popular deep learning models for TCM. Embedded soft and hard physical constraints can significantly reduce the training epochs of Transformer prediction model.

Tool wear prediction is of critical importance to maintain the desired part quality and improve productivity. Inspired by the successful application of deep learning in many condition monitoring tasks. In this article, a novel modeling framework is presented, which includes multiple stacked sparse autoencoders and a nonlinear regression function for tool wear prediction. Multiple stacked sparse autoencoders consists of two main structures. One model is designed with multidimensional stacked sparse autoencoders, which can learn more features from different feature domains in the raw vibration signal, and another single-dimensional stacked sparse autoencoders is used for feature fusion and deeper features learning. And a modified loss function is applied that improves the learning ability. In addition, due to the good properties of tool wear process in nonstationarity and complex nonlinear, a nonlinear regression function is utilized to enhance the progressive tool wear prediction tasks. A dataset from a real manufacturing process is used to evaluate the performance of the proposed modeling framework. Experimental results show that tool wear can be predicted accurately and stably by the proposed tool wear predictive model, which outperforms the already developed methods.