Multi-Physics Monotone Score Transport for Unsupervised Domain Adaptation of Continuous Tool Wear Prediction

Cross-material continuous tool wear prediction is difficult because a model must preserve the physical wear scale, not only align high-dimensional sensor features. This limitation is critical in milling, where the target variable is the continuous flank wear width (VB) and material shift can distort the mapping from sensor response to wear magnitude. We address this problem by recasting cross-domain tool wear prediction as monotone wear-scale adaptation. We propose Multi-Physics Monotone Score Transport (MPMST), a monotone score transport framework that constructs a tool-wear-oriented score from sensor-derived candidate cues, transports the target-domain score onto the source-domain wear scale, and then predicts wear through isotonic regression. We also evaluate One-Physics Monotone Score Transport (OPMST), a force-only variant that uses the same score-transport pipeline with a restricted cue family. On Mondragon Unibertsitatea–Tool Condition Monitoring (MU-TCM) with two cross-material transfer tasks, the validation-driven MPMST configuration reduces mean absolute error by approximately 63% relative to Correlation Alignment (CORAL) and by approximately 31% relative to a physics-informed Gaussian process baseline. The results support monotone score construction and score transport as practical mechanisms for continuous tool wear prediction under domain shift, while also showing that MU-TCM is strongly force dominated.