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A Hybrid Deep Learning Framework for Fault Diagnosis in Milling Machines

Year: 2025

Type: article

Abstract: This paper presents a hybrid fault-diagnosis framework for milling cutting tools designed to address three persistent challenges in industrial monitoring: noisy vibration signals, limited fault labels, and variability across operating conditions. The framework begins by removing baseline drift from raw signals to improve the signal-to-noise ratio. Logarithmic continuous wavelet scalograms are then constructed to provide precise time-frequency localization and reveal fault-related harmonics. To enhance feature clarity, a Canny edge operator is applied, suppressing minor artifacts and reducing intra-class variation so that key diagnostic structures are emphasized. Feature representation is obtained through a dual-branch encoder, where one pathway captures localized patterns while the other preserves long-range dependencies, resulting in compact and discriminative fault descriptors. These descriptors are integrated by an ensemble decision mechanism that assigns validation-guided weights to individual learners, ensuring reliable fault identification, improved robustness under noise, and stable performance across diverse operating conditions. Experimental validation on real-world cutting tool data demonstrates an accuracy of 99.78%, strong resilience to environmental noise, and consistent diagnostic performance under variable conditions. The framework remains lightweight, scalable, and readily deployable, providing a practical solution for high-precision tool fault diagnosis in data-constrained industrial environments.

Source: Sensors

DOI: 10.3390/s25185866