Tool Health Monitoring Using Airborne Acoustic Emission and Convolutional Neural Networks: A Deep Learning Approach

Abstract

Tool health monitoring (THM) is in great focus nowadays from the perspective of predictive maintenance. It prevents the increased downtime due to breakdown maintenance, resulting in reduced production cost. The paper provides a novel approach to monitoring the tool health of a computer numeric control (CNC) machine for a turning process using airborne acoustic emission (AE) and convolutional neural networks (CNN). Three different work-pieces of aluminum, mild steel, and Teflon are used in experimentation to classify the health of carbide and high-speed steel (HSS) tools into three categories of new, average (used), and worn-out tool. Acoustic signals from the machining process are used to produce time–frequency spectrograms and then fed to a tri-layered CNN architecture that has been carefully crafted for high accuracies and faster trainings. Different sizes and numbers of convolutional filters, in different combinations, are used for multiple trainings to compare the classification accuracy. A CNN architecture with four filters, each of size 5 × 5, gives best results for all cases with a classification average accuracy of 99.2%. The proposed approach provides promising results for tool health monitoring of a turning process using airborne acoustic emission.