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<p>The complex interplay and inherent trade-off between energy consumption and efficiency in precision milling processes have emerged as critical technical bottlenecks impeding sustainable development. Traditional single-task prediction models are found to struggle with ensuring accurate energy consumption forecasts and satisfying process quality constraints, while lacking support for generalization and efficient optimization. Accordingly, a precision-milling spindle energy consumption prediction model integrating multi-task learning (MTL) with the XGBoost ensemble algorithm is proposed. First, a precision-milling energy consumption prediction model providing a 95% confidence interval was constructed. By incorporating cross-task feature sharing within the MTL framework, high-precision predictions of spindle energy consumption, machine noise, and material removal rate (MRR) were achieved. Second, a multi-objective optimization model combining a genetic algorithm (GA) and particle swarm optimization (PSO) was developed, effectively addressing traditional algorithms’ susceptibility to local optima and slow convergence. Furthermore, the entropy-weighted TOPSIS method was applied for the comprehensive evaluation and ranking of the Pareto solution set, enabling the identification of optimal cutting parameter combinations that satisfy process requirements and guide milling operations. As a result, a 14.01% reduction in spindle energy consumption, a 14.37% increase in machining efficiency, and a 15.21% reduction in machining noise were achieved. These research outcomes can foster theoretical innovation and facilitate engineering applications in advanced energy efficiency management for digital manufacturing equipment.</p>

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Integrated multi-task learning and ensemble models for energy consumption prediction and optimization in precision milling spindles

  • 期刊论文

  • 发表日期：

    2026年5月12日

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  • Chenyang Shi,
  • Yang Xie,
  • Jianzhao Wu,
  • Chaoyong Zhang

摘要

The complex interplay and inherent trade-off between energy consumption and efficiency in precision milling processes have emerged as critical technical bottlenecks impeding sustainable development. Traditional single-task prediction models are found to struggle with ensuring accurate energy consumption forecasts and satisfying process quality constraints, while lacking support for generalization and efficient optimization. Accordingly, a precision-milling spindle energy consumption prediction model integrating multi-task learning (MTL) with the XGBoost ensemble algorithm is proposed. First, a precision-milling energy consumption prediction model providing a 95% confidence interval was constructed. By incorporating cross-task feature sharing within the MTL framework, high-precision predictions of spindle energy consumption, machine noise, and material removal rate (MRR) were achieved. Second, a multi-objective optimization model combining a genetic algorithm (GA) and particle swarm optimization (PSO) was developed, effectively addressing traditional algorithms’ susceptibility to local optima and slow convergence. Furthermore, the entropy-weighted TOPSIS method was applied for the comprehensive evaluation and ranking of the Pareto solution set, enabling the identification of optimal cutting parameter combinations that satisfy process requirements and guide milling operations. As a result, a 14.01% reduction in spindle energy consumption, a 14.37% increase in machining efficiency, and a 15.21% reduction in machining noise were achieved. These research outcomes can foster theoretical innovation and facilitate engineering applications in advanced energy efficiency management for digital manufacturing equipment.