Dimensional Error Prediction of Grinding Process Based on Bagging–GA–ELM with Robust Analysis

Grinding, which determines the final dimension of parts, is an important process in manufacturing companies. In praxis, in order to avoid quality problems on the customer’s side, an online dimension check is normally used after the grinding process to ensure the product dimensions; however, it is always hysteretic and needs extra space and machine investment. To deal with the issue, dimensional error prediction of the grinding process is highly needed, and does not require extra space or machinery, as well as having better real-time performance. In this paper, a dimensional error prediction algorithm using principal component analysis (PCA), extreme learning machine (ELM), genetic algorithm (GA), and ensemble strategy (bagging algorithm) is designed. Specifically, PCA is used as a pre-treatment method to extract the main relevant components, then a bagging–GA–ELM model is constructed to predict the final product dimensional error after the grinding process, in which extreme learning machine (ELM) is utilized as a basic framework because of its fast calculation speed. GA, with its excellent global optimization capability, is implemented to search optimal input weights and thresholds of ELM, enabling ELM to obtain a better prediction performance. In addition, considering the complex environment of the industrial field, the bagging algorithm is employed to enhance the anti-noise ability of the proposed algorithm. Finally, the proposed algorithm is verified by a case from a bearing company.