An increase in unplanned downtime of machines disrupts and degrades the industrial business, which results in substantial credibility damage and monetary loss. The cutting tool is a critical asset of the milling machine; the failure of the cutting tool causes a loss in industrial productivity due to unplanned downtime. In such cases, a proper predictive maintenance strategy by real-time health monitoring of cutting tools becomes essential. Accurately predicting the useful life of equipment plays a vital role in the predictive maintenance arena of industry 4.0. Many active research efforts have been done to estimate tool life in varied directions. However, the consolidated study of the implemented techniques and future pathways is still missing. So, the purpose of this paper is to provide a systematic and comprehensive literature survey on the data-driven approach of Remaining Useful Life (RUL) estimation of cutting tools during the milling process. The authors have summarized different monitoring techniques, feature extraction methods, decision-making models, and available sensors currently used in the data-driven model. The authors have also presented publicly available datasets related to milling under various operating conditions to compare the accuracy of the prediction model for tool wear estimation. Finally, the article concluded with the challenges, limitations, recent advancements in RUL prognostics techniques using Artificial Intelligence (AI), and future research scope to explore more in this area.

The induction motor plays a vital role in industrial drive systems due to its robustness and easy maintenance but at the same time, it suffers electrical faults, mainly rotor faults such as broken rotor bars. Early shortcoming identification is needed to lessen support expenses and hinder high costs by using failure detection frameworks that give features extraction and pattern grouping of the issue to distinguish the failure in an induction motor using classification models. In this paper, the open-source dataset of the rotor with the broken bars in a three-phase induction motor available on the IEEE data port is used for fault classification. The study aims at fault identification under various loading conditions on the rotor of an induction motor by performing time, frequency, and time-frequency domain feature extraction. The extracted features are provided to the models to classify between the healthy and faulty rotors. The extracted features from the time and frequency domain give an accuracy of up to 87.52% and 88.58%, respectively, using the Random-Forest (RF) model. Whereas, in time-frequency, the Short Time Fourier Transform (STFT) based spectrograms provide reasonably high accuracy, around 97.67%, using a Convolutional Neural Network (CNN) based fine-tuned transfer learning framework for diagnosing induction motor rotor bar severity under various loading conditions.

The milling machine serves an important role in manufacturing because of its versatility in machining. The cutting tool is a critical component of machining because it is responsible for machining accuracy and surface finishing, impacting industrial productivity. Monitoring the cutting tool’s life is essential to avoid machining downtime caused due to tool wear. To prevent the unplanned downtime of the machine and to utilize the maximum life of the cutting tool, the accurate prediction of the remaining useful life (RUL) cutting tool is essential. Different artificial intelligence (AI) techniques estimate the RUL of cutting tools in milling operations with improved prediction accuracy. The IEEE NUAA Ideahouse dataset has been used in this paper for the RUL estimation of the milling cutter. The accuracy of the prediction is based on the quality of feature engineering performed on the unprocessed data. Feature extraction is a crucial phase in RUL prediction. In this work, the authors considers the time–frequency domain (TFD) features such as short-time Fourier-transform (STFT) and different wavelet transforms (WT) along with deep learning (DL) models such as long short-term memory (LSTM), different variants of LSTN, convolutional neural network (CNN), and hybrid models that are a combination of CCN with LSTM variants for RUL estimation. The TFD feature extraction with LSTM variants and hybrid models performs well for the milling cutting tool RUL estimation.

Fused deposition modeling (FDM), a method of additive manufacturing (AM), comprises the extrusion of materials via a nozzle and the subsequent combining of the layers to create 3D-printed objects. FDM is a widely used method for 3D-printing objects since it is affordable, effective, and easy to use. Some defects such as poor infill, elephant foot, layer shift, and poor surface finish arise in the FDM components at the printing stage due to variations in printing parameters such as printing speed, change in nozzle, or bed temperature. Proper fault classification is required to identify the cause of faulty products. In this work, the multi-sensory data are gathered using different sensors such as vibration, current, temperature, and sound sensors. The data acquisition is performed by using the National Instrumentation (NI) Data Acquisition System (DAQ) which provides the synchronous multi-sensory data for the model training. To induce the faults, the data are captured under different conditions such as variations in printing speed, temperate, and jerk during the printing. The collected data are used to train the machine learning (ML) and deep learning (DL) classification models to classify the variation in printing parameters. The ML models such as k-nearest neighbor (KNN), decision tree (DT), extra trees (ET), and random forest (RF) with convolutional neural network (CNN) as a DL model are used to classify the variable operation printing parameters. Out of the available models, in ML models, the RF classifier shows a classification accuracy of around 91% whereas, in the DL model, the CNN model shows good classification performance with accuracy ranging from 92 to 94% under variable operating conditions.

In modern manufacturing, milling and micromilling processes play a central role in precision production. However, rapid wear of cutting tools often leads to sudden tool breakage, unplanned downtime, and part rejection. Maintenance is therefore essential to ensure efficiency, safety, and cost-effectiveness across industries. Traditional maintenance strategies have gradually evolved into predictive maintenance approaches supported by advanced technologies, creating a strong industrial demand for accurate and reliable predictive solutions. This review systematically analyzes studies from the past decade on predictive maintenance in milling and micromilling processes, with a particular focus on the performance of machine learning and deep learning algorithms integrated with computer vision techniques. The study evaluates model performance, prediction accuracy, and industrial applicability to identify key strengths and existing research gaps. The findings indicate that multi-sensor data fusion, deep learning methods, and hybrid models achieve the highest performance in tool wear monitoring and remaining useful life prediction of cutting tools.