Vibration Based Tool Insert Health Monitoring Using Decision Tree and Fuzzy Logic

The productivity and quality in the turning process can be improved by utilizing the predicted performance of the cutting tools. This research incorporates condition monitoring of a non-carbide tool insert using vibration analysis along with machine learning and fuzzy logic approach. A non-carbide tool insert is considered for the process of cutting operation in a semi-automatic lathe, where the condition of tool is monitored using vibration characteristics. The vibration signals for conditions such as heathy, damaged, thermal and flank were acquired with the help of piezoelectric transducer and data acquisition system. The descriptive statistical features were extracted from the acquired vibration signal using the feature extraction techniques. The extracted statistical features were selected using a feature selection process through J48 decision tree algorithm. The selected features were classified using J48 decision tree and fuzzy to develop the fault diagnosis model for the improved predictive analysis. The decision tree model produced the classification accuracy as 94.78% with five selected features. The developed fuzzy model produced the classification accuracy as 94.02% with five membership functions. Hence, the decision tree has been proposed as a suitable fault diagnosis model for predicting the tool insert health condition under different fault conditions.