- Article
Predictive Modeling of Tool Wear and Mass in Honing Processes Using Machine Learning and Grain Size Optimization
- Vlad Gheorghita
The increasing demand for energy efficiency in manufacturing has driven the need for advanced modeling techniques to optimize the machining processes. The honing process, critical for achieving high-precision surface finishes in manufacturing, faces challenges in optimizing tool wear and material removal for enhanced sustainability and efficiency. This study develops a predictive modeling framework using machine learning techniques, including support vector regression (SVR), random forest (RF), and XGBoost, to forecast tool wear (h1–h8) and mass loss in honing processes. Experimental tests were conducted on EN-GJL-300 gray cast-iron workpieces using diamond abrasive blades (FEPA F120 and F240) under varied conditions (rotation speed, translation speed, and pressure). The models, trained with 5-fold cross-validation and hyperparameter tuning via GridSearchCV, achieved high accuracy, with SVR yielding R2 values of 0.9609–0.9782 for wear predictions and XGBoost achieving R2 of 0.9005 for mass predictions. Incorporating grain size as a predictor showed that finer grains (54 µm vs. 120 µm) reduced wear, thereby improving prediction reliability. The proposed models enable precise control of honing parameters, enhancing tool life and process efficiency, with implications for sustainable manufacturing in automotive and precision engineering applications.
17 November 2025





