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System for Prediction Of Remaining useful life of Tool (SPORT)

In advanced manufacturing industries, there are increased requirements for predictive maintenance technologies. Predictive maintenance refers to maintenance performed after the occurrence of fault but before failure. Using such technologies, we can potentially improve the reliability, availability and productivity of systems. In adopting predictive maintenance, the key is to accurately estimate the trends of the health degradation and predict the Remaining Useful Life (RUL) through prognostics modelling. This will ultimately facilitate effective operations planning and timely maintenance.

In essence, SPORT is an end-to-end system capable of predicting and estimating the RUL of inserts, using raw vibration signals during the cutting process. SPORT has been developed with pre-trained models for predicting the state and RUL of the insert whereby these models are independent of the cutting speeds.

The novelty of SPORT as follows:

  1. Relative degradation for each cut in determining the tool wear
  2. Unified model capable of estimating the tool wear / RUL under different cutting speeds


  • Improve accuracy in RUL prediction
  • Able to deal with uncertainties from sensor data
  • Model-based RUL prediction under varying operating settings
  • Real-time dashboard for tool wear conditions

The Science Behind

SPORT is a unified data-driven model capable of accurately predicting the tool wear using only off-line tool wear data and on-line sensor observations. In generating the unified model applicable across different cutting speeds, individual machine learning models for each cutting speed served as inputs and had their parameters aggregated in the final model. Using data from vibration signals, results from the analyses showed that the model would accurately predict and estimate the RUL of the tool wear. Furthermore, since the unified model is built on being invariant across cutting conditions, it is suitable for different scenarios while using minimal data.

Industry Applications

SPORT could benefit industries in their push to adopt IIoT technologies within their shop floors and integrate devices with cutting tools such as grinding machines, drilling machines, etc.


 For more info or collaboration opportunities, please write to enquiry@ihpc.a-star.edu.sg