Abstract
To address the challenge of accurately capturing tool wear states in small sample scenarios, this paper proposes a tool wear prediction method that combines XGBoost feature selection with a PSO-BP network. In order to solve the problem of input feature selection and parameter selection in BP neural network, a double-layer programming model of input feature and parameter selection is established, which is solved by XGBoost and PSO. Initially, vibration and cutting force signals from CNC machining are preprocessed using time-domain segmentation, Hampel filtering, and wavelet denoising. Subsequently, time-domain, frequency-domain, and time-frequency domain features are extracted from the preprocessed data using FFT and wavelet packet decomposition, followed by feature screening for tool wear mapping via Pearson correlation and XGBoost feature importance analysis as model input. Finally, PSO is employed to optimize BPNN parameters. Experimental results show that PSO outperforms other algorithms in training the tool wear prediction model, with XGBoost feature selection reducing model construction time by 57.4% and increasing accuracy by 63.57%, demonstrating superior feature selection capabilities over Decision Tree, Random Fores, Adaboost and Extra Trees. These findings suggest that the proposed method can effectively predict tool wear in real-world CNC machining, contributing to improved production efficiency, reduced tool replacement frequency, and lower maintenance costs, thereby providing valuable insights for industrial applications.