Stability modeling for chatter avoidance in self-aware machining: an application of physics-guided machine learning

Physics-guided machine learning (PGML) offers a new approach to stability modeling during machining that leverages experimental data generated during the machining process while incorporating decades of theoretical process modeling efforts. This approach addresses specific limitations of machine learning models and physics-based models individually. Data-driven machine learning models are typically black box models that do not provide deep insight into the underlying physics and do not reflect physical constraints for the modeled system, sometimes yielding solutions that violate physical laws or operational constraints. In addition, acquiring the large amounts of manufacturing data needed for machine learning modeling can be costly. On the other hand, many physical processes are not completely understood by domain experts and have a high degree of uncertainty. Physics-based models must make simplifying assumptions that can compromise prediction accuracy. This research explores whether data generated by an uncertain physics-based milling stability model that is used to train a physics-guided machine learning stability model, and then updated with measured data, domain knowledge, and theory-based knowledge provides a useful approximation to the unknown true stability model for a specific set of factory operating conditions. Four novel strategies for updating the machine learning model with experimental data are explored. These updating strategies differ in their assumptions about and implementation of the type of physics-based knowledge included in the PGML model. Using a simulation experiment, these strategies achieve useful approximations of the underlying true stability model while reducing the number of experimental measurements required for model update.