In manufacturing processes using computerized numerical control (CNC) machines, machine tools are operated repeatedly for a long period for machining hard and difficult-to-machine materials, such as stainless steel. These operating conditions frequently result in tool breakage. The failure of machine tools significantly degrades the product quality and efficiency of the target process. To solve these problems, various studies have been conducted for detecting faults in machine tools. However, the most related studies used only the univariate signal obtained from CNC machines. The fault-detection methods using univariate signals have a limitation in that multivariate models cannot be applied. This can restrict in performance improvement of the fault detection. To address this problem, we employed empirical mode decomposition to construct a multivariate dataset from the univariate signal. Subsequently, auto-associative kernel regression was used to detect faults in the machine tool. To verify the proposed method, we obtained a univariate current signal measured from the machining center in an actual industrial plant. The experimental results demonstrate that the proposed method successfully detects faults in the actual machine tools.

Machining processes are critical and widely used components in the manufacturing industry because they help to precisely make products and reduce production time. To keep the previous advantages, a machine tool should be installed at the designated place and condition of the machine tool should be maintained appropriately to working environment. In various maintenance methods for keeping the condition of machine tool, condition-based maintenance can be robust to unpredicted accidents and reduce maintenance costs. Tool monitoring and diagnosis are some of the most important components of the condition based maintenance. This paper proposes stacked auto-encoder based CNC machine tool diagnosis using discrete wavelet transform feature extraction to diagnose a machine tool. The diagnosis model, which only uses cutting force data, cannot sufficiently reflects tool condition. Hence, we modeled diagnosis model using features extracted from a cutting force, a current signal, and coefficients of the discrete wavelet transform. The experimental results showed that the model which uses feature data has better performance than the model that uses only cutting force data. The feature based models are lower false negative rate (FNR) and false positive rate. Moreover, squared prediction error using normalized residual vector also reduced FNR because normalization reduces weight bias.

This paper studies the application of artificial intelligence to milling machines, focusing specifically on identifying the inputs (features) required for predicting surface roughness. Previous studies have extensively reviewed and presented useful features for surface roughness prediction. However, applying research findings to actual operational factories can be challenging due to the additional costs of sensor installations and the diverse environments present in each factory setting. To address these issues, in this paper, we introduced effective features for predicting surface roughness in situations where additional sensors are not installed in the existing environment. These features include feed per tooth, $F_z$; material removal rate, Q; and the load information. These features are suitable for use in highly constrained environments where separate sensor installation is not required, making it possible to apply the research findings in various factory environments. Additionally, to efficiently select the optimal subset for surface roughness prediction among subsets formed by available features, we apply causality to the feature selection method, proposing an approach called causality-driven efficient feature selection. The experimental results demonstrate that the features introduced in this paper are quite suitable for predicting surface roughness and that the proposed feature selection approach is more effective and efficient compared to existing selection methods.

Fault diagnosis in Computer Numerical Control (CNC) machines remains challenging due to severe class imbalance, scarcity of fault data, and distribution shifts across machines. This paper introduces Undersampling-based Few-shot Learning (UnderFSL), a simple yet effective framework that integrates strategic undersampling using Condensed Nearest Neighbor (U-CNN) with a Relation Network few-shot classifier. The proposed method first transforms raw 1D vibration signals into 2D Continuous Wavelet Transform (CWT) scalograms to capture time–frequency structure and then reduces the majority (normal) class using U-CNN, yielding a compact set of boundary-informative prototypes while alleviating imbalance. Finally, a Relation Network is trained in an episodic FSL regime on the balanced set to support cross-machine generalization. On the Bosch CNC machining benchmark under leave-one-machine-out validation, UnderFSL attains a macro F1-Score of 0.96, an accuracy of 0.96, a recall of 0.92, and a precision of 1.00, surpassing traditional and standard deep baselines. The results suggest that boundary-preserving undersampling combined with metric learning provides a robust and scalable path for industrial fault diagnosis when fault data are extremely limited.