Research on Tool Wear Monitoring Technology Based on Variational Mode Decomposition and Back Propagation Neural Network Model

Accurately predicting tool wear during the machining process not only saves machining time and improves efficiency but also ensures the production of good-quality parts and automation. This paper proposes a combined variational mode decomposition (VMD) and back propagation (BP) neural network model (VMD-BP), which maps spindle power to tool wear. The model is trained using both historical and real-time data. To improve accuracy, the internal power data from the machine tool are used to calibrate the model's input data. Data collected from milling experiments are used to test the model, with sensor-collected power being compared to the model's predicted power. The average error was 1.1256%, which confirms the reliability of the model. In practical applications, the model enables the real-time monitoring of spindle power, helping prevent excessive tool wear during machining. This offers significant guidance for actual production processes.