OPEN ACCESS Asian Journal of Scientific Research

ISSN 1992-1454
DOI: 10.3923/ajsr.2016.1.12

Research Article
Need for Adaptive Signal Processing Technique for Tool Condition
Monitoring in Turning Machines
1
J. Emerson Raja, 1W.S. Lim, 1C. Venkataseshaiah, 2C. Senthilpari and 3S. Purushothaman

1
Faculty of Engineering and Technology, Multimedia University, Jalan Ayerkeroh Lama, Melaka, 75450, Malaysia
2
Faculty of Engineering, Multimedia University, Cyber Jaya, Kualalumpur, Malaysia
3
Institute of Technology, Haramaya University, Dire Dawa, Ethiyopia

Abstract
This study deals with a comparative study of the processing of tool-emitted sound signal using conventional signal processing technique,
FFT and an adoptive signal processing technique, HHT for Tool Condition Monitoring (TCM) in a turning machine. The tool-emitted sound
signal obtained for the purpose of TCM is used to classify the condition of the cutting tool insert into one of the three states: Fresh, slightly
worn and severely worn. Signal processing techniques are used in this study for extracting features from the tool-emitted sound to train
a Competitive Neural Network (CNN) for tool-wear classification. Results of the study show that the CNN trained by the features extracted
using HHT performs more accurate classification than the same CNN trained by the features extracted using FFT. Hence, this study leads
to the conclusion that adaptive signal processing technique, HHT is more suitable than FFT for designing accurate machine tool condition
monitoring systems.

Key words: Adaptive signal processing, competitive neural network, empirical mode decomposition, Hilbert Huang transform, tool condition monitoring

Received: April 27, 2015 Accepted: December 04, 2015 Published: December 15, 2015

Citation: J. Emerson Raja, W.S. Lim, C. Venkataseshaiah, C. Senthilpari and S. Purushothaman, 2016. Need for Adaptive Signal Processing Technique for Tool
Condition Monitoring in Turning Machines. Asian J. Sci. Res., 9: 1-12.

Corresponding Author: J. Emerson Raja, Faculty of Engineering and Technology, Multimedia University, Jalan Ayerkeroh Lama, Melaka, 75450, Malaysia
Tel: 006062523235, 0060166437161 (HP) Fax: 006062316552

Copyright: © 2016 J. Emerson Raja et al. This is an open access article distributed under the terms of the creative commons attribution License, which
permits unrestricted use, distribution and reproduction in any medium, provided the original author and source are credited.

Competing Interest: The authors have declared that no competing interest exists.

Data Availability: All relevant data are within the paper and its supporting information files.
 Asian J. Sci. Res., 9 (1): 1-12, 2016
INTRODUCTION
The costs of machineries in industry have been
increasing and their efficient use depends on reducing the
operating and maintenance costs. To satisfy this requirement,
condition monitoring and diagnosis of machinery and process
has become essential in almost all the industries. Tool
Condition Monitoring (TCM) is a kind of machine condition
monitoring system where, the condition of the cutting tool bit
is diagnosed through sensing and analysis of process
information such as tool sound, vibration, current, etc. In
practice, approximately 20% of the downtime of machine
tools is reported to be due to tool failure and the cost of
cutting tools and their replacement accounts for between
3 and 12% of total production costs (Ghani et al., 2011).
Another study reports that, tool wear measurement is a
complex procedure failure to which may lead to excessive
power consumption and surface degradation (Rehorn et al.,
2005). Sadettin et al. (2007) investigated the relationship
between vibration and tool wear using FFT signal analysis
and concluded that the amplitude of the vibration increases
steadily with the increasing tool wear. The FFT method is
widely used in the spectrum analysis of envelope signals;
however, it could only give the global energy-frequency
distributions and fail to reflect the details of a signal. So, it is
hard to analyze a signal effectively, when the fault signal is
weaker than the interfering signal (Che and Hu, 2010).
According to Huang et al. (1998) the Fourier transform
represents the global rather than any local properties of the
signal, because it employs a convolution integral through
which the signal is decomposed in terms of sine and cosine
functions covering uniformly the whole data span. Though
wavelet analysis is better than Fourier transform the
non-adaptive nature of it is found to be its limitation, i.e., once
the basic or mother wavelet is selected, it will be used to
analyse all the data which is not data dependent
(Che and Hu, 2010). Hilbert-Huang Transform (HHT) is
considered to have the potential of becoming a perfect
adaptive method for analyzing non-stationary and
non-linear data, which is derived from the principles of
Empirical Mode Decomposition (EMD) and the Hilbert
transform (Sun et al., 2003). The strength of the HHT for
industry data lies in its ability to preserve phase and
amplitude while, empirically separating signal from noise
(Battista et al., 2007). In this study, a comparison of the
performance of HHT signal processing technique and the
traditional FFT signal processing technique is made for
machine tool condition monitoring using tool-emitted sound
signal in a turning machine.
2
MATERIALS AND METHODS
Digital signal processing is a modern technique of using
computers to analyse signals, such as voltage pulses
generated by the heart and brain, radar and sonar echoes,
seismic vibrations, emitted sound from machines and many
others. The only link with the unexplained reality is the data
or signals. Hence, data/signal processing is the only way using
by which, it can come to know the underlying processes of
any given phenomenon (Huang and Wu, 2008). In order to
understand thoroughly the physical mechanisms
hidden in signals, the complexity in non-stationary and
non-linearity of the signals should be properly dealt with.
A better approach to dealing non-linearity and non-stationary
in signals is to allow the signal speak for themselves and not
to allow the analyzer enforce irrelevant mathematical rules; in
other words, the method of analysis must be adaptive to the
nature of the signal. Hence, a true data decomposing method
must have adaptive basis. Here, adaptivity implies that the
definition of the basis should be based on and deduced from
the signal (Huang et al., 1998). Signal processing method
should use posteriori-defined basis (derived from data) not a
priori defined basis.
The Hilbert-Huang Transform (HHT) is a new approach to
signal processing, which works well for signals that are
non-stationary and non-linear as the definition of the basis is
derived from the signal itself. It includes the decomposition
of a multi-component signal into several mono-component
signal, called Intrinsic Mode Functions (IMF) and obtaining the
instantaneous frequency data (Huang et al., 1998). The HHT is
more like an algorithm (an empirical approach) that can be
employed to any data set, rather than a hypothetical or a
theoretical tool.
The HHT is derived from the principles of Empirical Mode
Decomposition (EMD) and the Hilbert transform. First the EMD
will decompose the acquired non-stationary and non-linear
signal into a collection of IMFs. The IMF is a kind of adaptive
and nearly orthogonal representation for the analyzed signal.
All the instantaneous frequencies of the IMF can be
determined, because it is almost mono component. Second
the amplitude of each instantaneous frequency can be
derived through the Hilbert transform.
Hilbert-Huang Transform (HHT): For a real-valued signal x(t)
the Hilbert transform can be defined by the Principal Value
(PV) integral. The physically significant way to describe the
system is in terms of the instantaneous frequency, which will
reveal the intra wave frequency modulations. The simple and
straight forward to extract or calculate the instantaneous
 Asian J. Sci. Res., 9 (1): 1-12, 2016
frequency of a mono-component signal is by using Hilbert
transform (Huang and Wu, 2008). For an arbitrary signal or
time series x(t), its Hilbert transform y(t) is defined as Eq. 1:

p x()
y(t)   t  d
 
where, P is the Cauchy principal value of the singular
transform. This function exists for all functions of class of
Lebesgue spaces or LP. Equation 1 shows that the Hilbert
transform is determined as the convolution of the signal x(t)
with 1/t. Therefore, the Hilbert transform is able to identify the
local properties of x(t). The analytic signal z(t) of x(t) can be
formed as follows by coupling the x(t) and y(t) as in Eq. 2:
z(t) = x(t)+iy (t) = a(t)ein(t)
With Eq. 3:
1/2
a(t)   x 2 (t)  y 2 (t)  , (t)  arctan (y(t) / x(t))
where, a(t) is the instantaneous amplitude of x(t), which can
indicate how the energy of the x(t) varies with time and the
N(t) is the instantaneous phase of x(t). The arguable
instantaneous frequency T(t) can be defined as the time
derivative of the instantaneous phase N(t) as in Eq. 4:
d(t)
(t) 
dt
Because, the instantaneous frequency can be defined
through differentiation rather than integration it seems to be
local and can describe the intra-wave frequency modulation.
Therefore, Eq. 4 is helpful in extracting instantaneous
frequencies from any non-stationary signals. However, Eq. 4 is
only valid in getting the instantaneous frequency of a signal in
a given time frame, if the signal is mono-component within
the time frame. If the acquired signal is multi-component
within the defined time frame, the result of the instantaneous
frequency will be distorted (Rilling et al., 2003). Unfortunately,
in almost all of the practical applications, the inspected signals
are seldom mono-component but multi-component.
Therefore, to make the instantaneous frequency relevant, the
key is the ability to decompose the signal into some individual
mono-component signals. The empirical mode decomposition
provides such decomposition ability is a new two-step signal
processing technique derived by Huang et al. (1998) more
suitable for analyzing non-stationary and non-linear data.
Firstly, EMD is applied to decompose the given signal into
a set of complete and almost orthogonal components called
Intrinsic Mode Functions (IMF). Since the IMF is almost
mono-component, it can determine all the instantaneous
frequencies from a non-linear and non-stationary signal.
(1) Secondly, the local energy of each instantaneous frequency
component can be obtained through the Hilbert transform
(Peng et al., 2005). If the inspected signal is multi-component
within the defined time frame, the result of the instantaneous
frequency will be distorted (Rilling et al., 2003). Unfortunately,
in almost all of the practical applications, the inspected signals
are hardly mono-component but multi-component. Therefore,
to make the instantaneous frequency applicable, the key is the
ability to decompose the signal into some individual mono-
component signals. The empirical mode decomposition
provides such decomposition ability.
(2)
Empirical Mode Decomposition (EMD): Unfortunately, most
of the time the signals under investigation are not IMFs. At any
given time, the signals may involve more than one oscillatory
(3) mode; that is why, the simple Hilbert transform cannot
provide the full description of the frequency content for the
general signal (Huang and Wu, 2008). Hence, the signal needs
to be decomposed into mono-components (IMF) before
applying Hilbert transform. The EMD is a new method to
decompose non-stationary and non-linear signals into finite
sum of IMFs. This new method is intuitive, direct, a posteriori
and adaptive with the basis of the decomposition based on
and derived from, the data (Huang et al., 1998). The
decomposition is designed to seek the different simple
(4)
intrinsic modes of oscillations in any data based on the
principle of scale separation. The data, depending on it
complexity may have many different coexisting modes of
oscillation at the same time. Each of these oscillatory modes is
represented by an Intrinsic Mode Function (IMF) with the
following conditions:
C In the whole data set, the number of extrema and the
number of zero-crossings must either equal or differ at
most by one
C At any point, the mean value of the envelope defined by
the local maxima and the envelope defined by the local
minima is zero
The first condition is to ensure that the signal is with no
riding waves while, the second one is used to make sure that
the signal having slowly varying amplitude. A process called
sifting, introduced by Huang et al. (1998) is used to extract
every IMF from the multi-component signal. This sifting
process can be carried out as follows:
3
 Asian J. Sci. Res., 9 (1): 1-12, 2016
C All the local maxima of the given signal need to identify
first
C An upper envelope u(x) has to be formed by connecting
all of the local maxima by a cubic spline fitting
C Similarly a lower envelope l(x) has to be formed by
connecting all of the local minima by a cubic spline fitting
C The upper and lower envelopes should cover all the data
between them. Their local mean m1(t) can now be
calculated as in Eq. 5:
(m1(t) = [u(t)+l(t)]/2) (5)
C The difference between the data and their local mean
m1(t) is to be calculated as in Eq. 6:
h1(t) = x(t)-m1(t) (6)
The above mentioned steps, known as sifting process
have to be repeated as many times as it is required to
reduce the extracted signal to an IMF. In the subsequent
sifting process steps h1(t) is treated as the data; then Eq. 7 will
be as:
h11(t) = h1(t)-m11(t) (7)
where, m11(t ) is the mean of the upper and lower envelops of
h1(t). This process can be repeated up to k times; h1k(t) is then
given by Eq. 8:
h1k(t) = h1(k-1)(t)-m1k(t) (8)
After each processing step, checking must be done on
whether the number of zero crossings equals the number of
extrema. The resulting time series is the first IMF and then it is
designated as c1(t) = h1k(t). The first IMF component from the
data contains the highest oscillation frequencies found in the
original data x(t).
This first IMF is subtracted from the original data and this
difference is called a residue r1(t) given by Eq. 9:
r1(t) = x(t)-c1(t) (9)
The residue r1(t) is taken as if it was the original data and
apply to it again the sifting process. The process of finding
more intrinsic modes ci(t) continues until the last mode is
found. The final residue will be a constant or a monotonic
function as in Eq. 10:
n
x(t)   c j (t)  rn (t) (10)
j1
4
Thus, one achieves a decomposition of the data into
n-empirical IMF modes, plus a residue, rn(t), which can be
either the mean trend or a constant. Because each IMF is a
mono-component signal the Instantaneous Frequency (IF) and
Instantaneous Amplitude (IA) can now be obtained by
applying Hilbert transform.
Hilbert transform: Instantaneous Frequency (IF) and
Instantaneous Amplitude (IA) of IMF can be obtained by using
EMD, any arbitrary time series x(t) of length N can be
expressed as in Eq. 11:
x(t)  Re   nj  1 a j (t)e 
i wj( t )dt 
 (11)

where, Re[ ] is the real part of terms within brackets.
Equation 11 gives both amplitude and frequency of every
component as functions of time. The same data expanded in
a Fourier representation would be as in Eq. 11 and 12:
x(t)  Re   j  1 a j (t)eiwjt  (12)
where, both aj and wj are constants. The conceptual
separation between Eq. 11 and 12 is clear: The IMF represents,
to a large degree, a generalized Fourier expansion. The
variable amplitude and the instantaneous frequency not only
improve the efficiency of the expansion, but also enable the
expansion to accommodate non-linear and non-stationary
variations in data. The IMF expansion removes the restriction
of constant amplitude and fixed frequency in the Fourier
expansion, allowing a variable amplitude and frequency
representation along the time axis (Huang et al., 2003).
Equation 11 enables us to present the amplitude and
the instantaneous frequency in a three-dimensional
plot, where, the amplitude is the height (z-axis) in the
time-frequency plane. This time-frequency distribution is
named as the Hilbert spectrums given by Eq. 13:
n
H(, t)  Re  a i (t)e 
j w i ( t )dt
(13)
i 1
The Hilbert spectrum provides a measure of amplitude
contribution from each frequency and time. Hilbert spectrum
is a weighted non-normalized joint amplitude-frequency-time
distribution. The weight assigned to each time-frequency cell
is the local amplitude. A spike in the Hilbert spectrum
indicates the existence of such a wave at a particular instance
where, as it indicates only the existence of sinusoidal
component in the case of Fourier spectrum.
 Asian J. Sci. Res., 9 (1): 1-12, 2016
Marginal spectrum: With the Hilbert spectrum defined, the
marginal spectrum could be defined as in Eq. 14:
T transform respectively. Discrete Fourier Transform (DFT) is a
h()   H(, t)dt
0
where, T is the length of total signal.
The marginal spectrum provides a measure of the total
amplitude contribution from each frequency (Huang et al.,
1998; Zhang, 2006). Therefore, local marginal spectrum of
each IMF component can be defined as in Eq. 15:
T emitted sound. The microphone is connected to the computer
h i ()   H i (, t)dt
0
The local marginal spectrum provides a measure of the
total amplitude contribution from each frequency.
According to marginal spectrum, the prominent amplitude
of the tool flank wear can be easily recognized and thereby,
the state of the tool wear can easily be determined. The
frequency in the marginal spectrum indicates only the
likelihood that an oscillation with such a frequency exists. The
exact occurrence time of that oscillation is given by the full
Hilbert spectrum.
Fast Fourier transform: According to Fourier s theory any
periodic and complex wave form could be decomposed into
a collection of sinusoids with different frequencies, phases and
amplitudes. This decomposition is called Fourier analysis. The
result of this analysis is a set of frequencies, phases and
amplitudes for each of the sinusoids that build the complex
waveform. The original waveform can be reproduced exactly
by adding these sinusoids together again. A frequency
spectrum can then be produced by plotting of the frequency
or phase of a sinusoid against amplitude. The Fourier
transform (conversion from the time domain to the frequency
domain) is defined as in Eq. 16:
X(f )   
 x(t) e  i2 ft
dt
where, i is square root of -1, f is frequency in Hertz, t is time
in seconds, x(t) is complex function in the time domain, X(f)
is a complex function in the frequency domain and it is
defined as in Eq. 17:
ei 2 f  cos (2ft)  i sin (2ft)
The use of this Fourier theory for the conversion of the
signal from the time domain to the frequency domain and vice
versa is called Fourier transform and inverse Fourier
(14)
method of Fourier transform that can be applied to a
collection of real-world data points. The enhancement version
of DFT is called Fast Fourier Transform or simply FFT (Donnelly,
2006).
Experimental set-up: The schematic diagram of the
experimental setup is shown in Fig. 1. A PCB 130D20
microphone is kept facing towards the tool tip to capture the
(15) through a specially designed signal conditioner. Gold Wave
software running in the computer is used to record the
captured sound with sampling frequency set to 44100 Hz.
A series of machining experiments were conducted on a
conventional lathe with Carbide Insert NM6 and mild steel
work piece. First, a free run sound without the machining
operation was recorded for about 12 sec with constant cutting
parameters. Keeping the constant cutting parameters same,
the sound emitted due to the machining with a fresh tool with
no flank wear was recorded for about 12 sec. This recoding
process was repeated separately for slightly worn tool with
0.2 mm flank wear and severely worn tool with 0.4 mm flank
wear. These measurements were labeled as free run, fresh,
slightly worn and severely worn. The 12 sec long sound signal
is spitted into 12, one second sound signals for further signal
processing using HHT and FFT. Each one second signal
contains 44100 sampling data. The matlab waveread function
was used to digitize the sound signals for further analysis.
The proposed competitive neural network (Fig. 2) consists
of two neurons (IN1 and IN2) in the input unit and three
neurons (ON1, ON2 and ON3) in the output unit. The
Instantaneous Amplitude (IA) and the mean Instantaneous
Frequency (IF) of the selected IMF are given as input. The three
output neurons are representing the three different states of
the tool wear, fresh, slightly worn and severely worn. Each
(16) input neuron is connected to every output neuron thus
forming the weight matrix of 3×2. Winner takes all
unsupervised learning algorithm the Kohonen Learning Rule
(learnk from matlab) is used to update the weights of the
winning neuron (Hakimi-Asiabar et al., 2009). Supposing that
the ith neuron wins, the elements of the ith row of the input
weight matrix are adjusted as shown below in Eq. 18:
(17)
Wi new = Wi old+η (X-Wi old) (18)
5
 Asian J. Sci. Res., 9 (1): 1-12, 2016

Sound
recorder
software
BNC Signal BNC
Conditioner

Microphone

Tool insert
Work piece

Fig. 1: Experimental setup

Inter connection Output

Input unit with associated unit
weights

ON1 Initial
W11 wear
IA IN1
W21 W12
W31 ON2 Medium
wear
W22

IF IN2
ON3 Severe
wear
W32

Fig. 2: Proposed competitive neural network

where, Wi is the updated weights of the winning neuron i, Wi
old is the existing weights of the winning neuron. The
constant represents the learning rate for the weight
adjustments 0.5 is used in this experiment, It represents the
fraction of the distance that the winning neuron will move
toward the input data vector, X is input vector consists of IA
and IF.
RESULTS AND DISCUSSION
The competitive neural network used to classify the tool
wear was trained separately by features extracted from the
emitted tool sound signals using FFT and HHT. The
performance of each trained network was tested and the
results obtained are discussed in this section.
Testing the performance of the neural network trained by
features extracted using FFT: For this purpose, FFT is applied
on the sound signals generated from fresh, slightly and
severely worn tool and their power spectrums are
generated (Fig. 3a-c). The competitive neural network
was trained with 36 samples taking 12 each from fresh,
slightly worn and severely worn tool sound. Each sample is
a vector, consisting of amplitude and frequency of one
second sound signal extracted using FFT. The weights of
the three output neurons before and after training are
shown in Table 1. From Table 1 it is observed that output
neuron ON1 represents the fresh state of the tool, ON2
represents the severely worn state of the tool and ON3
represent the slightly worn state of the tool. This can be
clearly viewed from the graph (Fig. 4) plotted with the
training data and the weights of the three trained output
neurons.
Table 2 shows the details of performance of the neural
network trained by FFT features. The percentage of success
is only 47.2%, which is very low, when compared to the

6
 Asian J. Sci. Res., 9 (1): 1-12, 2016
(a) (b)

2.5 2.5

2.0 2.0
Amplitude

Amplitude
1.5 1.5

1.0 1.0

0.5 0.5

0.0 0.0
0 200 400 600 800 1000 1200 0 200 400 600 800 1000
Frequency (Hz) Frequency (Hz)

(c)

4
Amplitude

0
0 200 400 600 800 1000 1200
Frequency (Hz)

Fig. 3(a-c): FFT power spectrum of fresh (a) Slightly worn (b) Severely worn and (c) Tool sound signal collected at spindle speed
650 rev minG1 and 0.5 mm depth of cut

Table 1: Weights of the three output neurons before and after training by FFT features
Weights before training Weights after training
---------------------------------------------------------------- -----------------------------------------------------------------------------------
Output neurons Amplitude Frequency Amplitude Frequency
ON1 9.6350 387.50 1.2802 553.2031
ON2 9.6350 387.50 8.5579 253.1081
ON3 9.6350 387.50 6.5544 356.5524

Table 2: Performance of the neural network trained by FFT features

Testing
---------------------------------------------------------------------------------------------------------------------------------------------------------------------
Category Samples used Correct classification Accuracy (%)
Fresh 12 3 25
Slightly worn 12 4 33.3
Severely worn 12 10 83.3
Overall accuracy 47.2

7
 Asian J. Sci. Res., 9 (1): 1-12, 2016

Tool flank wear classification

20

18

16

14

12

Amplitude
10
ON2
8
ON3
6

2
ON1
0
150 200 250 300 350 400 450 500 550 600 650
Frequency
Fresh
Slightly worn
Seveley worn
Weight of the neuron representing fresh tool state ON1
Weight of the neuron representing slightly worn tool state ON2
Weight of the neuron representing severely worn tool state ON3

Fig. 4: FFT based tool flank wear classification

Table 3: Weights of the three output neurons before and after training by HHT features
Weights before training Weights after training
--------------------------------------------------------- ----------------------------------------------------------------------------------------
Output neurons Amplitude Frequency Amplitude Frequency
ON1 0.25 375.00 0.1536 447.0
ON2 0.25 375.00 0.2039 355.4
ON3 0.25 375.00 0.2694 285.8

percentage of success (83.32%) of the CNN trained by features
extracted using HHT.
Feature extraction using HHT: The original multi-component
sound signal of the severely worn tool is shown in Fig. 5a.
It contains various components such as sound emitted from
machine rotational parts and the much needed sound emitted
due to the contact between the tool flank face and the surface
of the work piece. In addition to these components, it also
contains the harmonics of the fundamental signals of this
kind. In order to extract the features that reveal the true nature
of the tool, this multi-component signal is decomposed into
several mono-component signals, the IMFs, using EMD. The
result of the application of EMD on severely worn tool
sound signal is shown in the form of 14 IMFs and a residue in
Fig. 5b.
The marginal spectrum of IMF 6 for fresh, slightly and
severely worn tool sound signals, collected at spindle speed
650 rev minG1 and 0.5 mm depth of cut are shown in
Fig. 6a-c. The maximum amplitude of sound emitted with the
fresh, slightly and severely worn tool bit insert is measured as
0.376, 0.532 and 0.632, respectively. These findings show that
the increase of sound pressure amplitude is co-related to the
increase in tool flank wear, which is in agreement with the
work done by Altin et al. (2007). The increase in the sound
pressure amplitude is due to the higher frictional forces
between tool and work piece. When the tool gradually wears,
the flank surface becomes larger, causing the contact surface
between tool and work piece to increase and resulting in
higher frictional forces. It is also observed that the frequency
is reducing (326, 291 and 259 Hz), with the development of
the tool flank wear. This correlation is found true for signals
collected at different cutting conditions. Even though the
relation is not linear, this difference is sufficient to train the
competitive neural network to classify the state of the wear.
Testing the performance of the neural network trained by
features extracted using HHT: The weights of the three
output neurons before and after training are shown in
Table 3. From Table 3 it is observed that Output Neuron ON1
represents the fresh state of the tool, because their weights
are closer to the IA and IF of fresh tool sound. This neuron will
fire, whenever a sound signal from fresh tool is input to this
network. Similarly ON2 and ON3 represent the slightly

8
 Asian J. Sci. Res., 9 (1): 1-12, 2016

(b) Empirical mode decomposition

RES. IMF14 IMF13 IMF12 IMF11IMF10 IMF9 IMF8 IMF7 IMF6 IMF5 IMF4 IMF3 IMF2 IMF1 SIGNAL
0.8
(a)
0.6

0.4

0.2
Amplitude

0.0

-0.2

-0.4

-0.6

-0.8
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5
Sampled time V104

Fig. 5(a-b): (a) Original multi-component severely worn tool sound signal and (b) Its decomposition (14 IMFs) using EMD

(a) 0.7
(b)

0.6
0.6
X = 291.7758
Y = 0.53228
0.5
0.5
Instantaneous amplitude

X = 326.4191
Instantaneous amplitude

0.4 Y = 0.37603
0.4

0.3
0.3

0.2
0.2

0.1
0.1

0
0
0 200 400 600 800 1000 0 500 1000
Instantaneous frequency (Hz) Instantaneous frequency (Hz)

Fig. 6(a-c): Continue

9
 Asian J. Sci. Res., 9 (1): 1-12, 2016

0.7
(c)

0.6 X = 259.9512
Y = 0.63238

0.5

Instantaneous amplitude
0.4

0.3

0.2

0.1

0
0 500 1000
Instantaneous frequency (Hz)

Fig. 6(a-c): Marginal spectrum of IMF 6 for fresh (a) Slightly worn (b) Severely worn and (c) Tool sound signal collected at spindle
speed 650 rev minG1 and 0.5 mm depth of cut

Tool flank wear classification

0.45

0.40
RMS instantaneous amplitude

0.35

0.30
ON3
0.25

0.20 ON2

0.15
ON1

0.1
250 300 350 400 450 500
Mean instantaneous frequency
Fresh
Slightly worm
Seveley worm
Weight of the neuron representing fresh tool state (ON1)
Weight of the neuron representing slightly worn tool state (ON2)
Weight of the neuron representing severely worn tool state (ON3)

Fig. 7: HHT based tool flank wear classification

worn and severely worn states of the tool, respectively. than the percentage of success achieved (47.2%) from the
This can be clearly viewed from the graph (Fig. 7) plotted with CNN trained by features extracted using FFT.
the training data and the weights of the three trained Better results are achieved, because HHT is not
output neurons. constrained by the assumptions of stationarity and linearity,
Table 4 shows the details of performance of the neural required for the FFT. From the Fig. 4, it is evident that the FFT
network trained by features extracted using HHT. A reasonably fails to reveal frequency variations of the tool sound signals as
good percentage of success 83.3% was achieved. It is better they are nonlinear and non-stationary in nature.

10
 Asian J. Sci. Res., 9 (1): 1-12, 2016
Table 4: Performance of the neural network trained by HHT features
Testing
---------------------------------------------------------------------------------------------------------------------------------------------------------------------
Category Samples used
Fresh 12
Slightly worn 12
Severely worn 12
Overall accuracy
From Fig. 6, it is evident that the amplitude of the
recorded sound increases with the increase of tool wear,
which is in agreement with the conclusion of Kopac and Sali
(2001). They concluded that an increase in tool wear correlates
with an increase in amplitude of the recorded sound.
Li et al. (2011) concluded that people can monitor the
wear state of tool using the features such as energy and peak
of appropriate IMF (IMF 3) extracted from drilling noise using
HHT transformation. In this study, it is found that tool wear
classification is also possible in turning machines using the
features, such as peak of appropriate IMF (IMF 6) and
frequency, extracted from tool sound using HHT.
Trabelsi and Kannatey-Asibu (1991) used a condenser
microphone to record the sound pressure signal of sharp,
worn and breakage tool sounds of a 30 hp American lathe.
They sampled the signals at 40 kHz and Fourier-transformed
them before being used for classification. They managed to
achieve a classification rate of 80%. But in this study, because
of HHT a reasonably good percentage of classification rate,
83.3%, was achieved.
CONCLUSION
In this study, an attempt is made to verify whether, HHT
signal processing technique is more suitable than the
traditional FFT for the application of machine tool condition
monitoring. The monitoring process involved collecting tool
emitted sound signals using a microphone, extracting the
features from the emitted tool sound signals corresponding to
fresh, slightly worn and severely worn tool inserts; then
training and testing the CNN using these features. It was found
that the CNN trained by the features extracted using HHT
performs better classification than the CNN trained by features
extracted using FFT. Hence, it can be concluded that adaptive
signal processing technique, HHT is more suitable than FFT for
designing accurate machine tool condition monitoring
systems.
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