International Research Journal of Innovations in Engineering and Technology (IRJIET)
ISSN (online): 2581-3048
Volume 9, Special Issue INSPIRE’25, pp 349-354, April-2025
https://doi.org/10.47001/IRJIET/2025.INSPIRE56
International Conference on Sustainable Practices and Innovations in Research and Engineering (INSPIRE'25)
Tool Wear and Fault Diagnosis and Prognostics
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1
M. Amareswara Kumar, 2G. Jayasai Karthik, 3D. Hussain Basha, 4S. Ashraf, 5P. Ramesh, 6O. Yogeeswar, 7K. Chaitanya
1
Assistant Professor, Department of Computer Science & Engineering, Santhiram Engineering College, Nandyal, A.P., India
2,3,4,5,6,7
UG Student, Department of Computer Science & Engineering, Santhiram Engineering College, Nandyal, A.P., India
Abstract - Tool wear and fault detection are paramount to facilitate early maintenance. This AI-powered tool wear and
manufacturing operation effectiveness and dependability. fault diagnosis and prognostics, which is developing by using
The project suggests an artificial intelligence system for Machine Learning (ML) and Deep Learning (DL) to monitor
real-time tool wear prediction and fault prognostics using diagnose and predict tool wear and faults in real time
unsupervised learning and advanced data-driven methods. condition. Mainly using the clustering algorithms for the
The system monitors data from sensors, including detecting tool wear and fault conditions in the machinery. This
vibration, temperature, and acoustic emissions, embedded increases tool life, reduces unplanned downtime, enhance
within the machinery. Clustering algorithms, anomaly product quality and improves manufacturing productivity.
detection algorithms, and dimensionality reduction
algorithms (such as K-means, DBSCAN, and PCA) are II. TOOL WEAR AND FAULT DIAGNOSIS AND
applied to detect patterns and anomalies in tool behaviour PROGNOSTICS
in the absence of label data. Reinforcement learning (RL)
Tool Wear and Fault Diagnosis and Prognostics
algorithms are applied to optimize maintenance policies by
(TWFD&P) driven by AI is the computerized process of
learning machine interactions continuously. This
tracking, detecting, and forecasting the wear and faults
autonomous mechanism facilitates early fault detection,
occurring in machining tools utilizing artificial intelligence
minimizes surprise failures, and maximizes overall
models. Utilizing clustering, the system detects patterns in
manufacturing productivity and cost-effectiveness.
sensor signals to classify similar wear conditions or fault states
Keywords: Principal Component Analysis, Clustering so that effective fault diagnosis and prognostics are achieved.
algorithms, reinforcement learning algorithms, K-means
Tool Wear: Progressive loss of material due to friction, heat,
clustering, dimensionality reduction.
and cutting forces during machining.
I. INTRODUCTION
Fault Diagnosis: Recognizing and categorizing tool anomalies
Tool wear and fault diagnosis are main issues with or failures (e.g., chipping, breakage).
contemporary manufacturing enterprises having a direct
Prognostics: Predicting the Remaining Useful Life (RUL) of
influence on quality of product and business costs alongside
the tool to enable predictive maintenance.
productivity. Universal maintenance practices historically
relied on reactive or preventive principles to catch production A. Design of the System:
unawares or resource wastage. The development of Artificial
Intelligence (AI) technology has advanced predictive and The AI-powered Tool Wear and Fault Diagnosis and
prognostic techniques via tool condition real-time monitoring Prognostics (TWFD&P) system utilizes data acquisition, data
and prior-to-runtime tool degradation forecasting. The purpose preprocessing, clustering algorithms, fault diagnosis, tool wear
of this work is to implement a tool wear and fault prediction prognostics and reporting.
system based on AI without invoking supervised learning
algorithms. Rather, it employs unsupervised and semi-
supervised techniques such as clustering, anomaly detection,
and generative models to employ for pattern detection and
anomalies of the sensor signals. With continuous or
simultaneously observation of the vibration, temperature, and
acoustic emission signals (sound signals), the system can
detect aberrations, forecast potential faults, and thereby
Fig. 1: Architecture of the System
© 2025 IRJIET All Rights Reserved www.irjiet.com 349
International Research Journal of Innovations in Engineering and Technology (IRJIET)
ISSN (online): 2581-3048
Volume 9, Special Issue INSPIRE’25, pp 349-354, April-2025
https://doi.org/10.47001/IRJIET/2025.INSPIRE56
International Conference on Sustainable Practices and Innovations in Research and Engineering (INSPIRE'25)
1) Sensor data: The Tool Wear and Fault Diagnosis and nominal operation with no wear, Cluster 2 is slight wear,
Prognostics (TWFD&P) system employs real-time data Cluster 3 is moderate wear with increasing vibration, and
collection using multiple sensors attached on machining tools. Cluster 4 is heavy wear or failure imminent. Moreover,
Vibration sensors pick up abnormal vibration due to tool wear anomaly detection also recognizes abnormal wear pattern or
or misalignment, and acoustic emission sensors quantify noise outliers and can be a symptom of precipitous faults such as
levels for detecting subtle changes due to wear. Force/torque breakage or chipping.
sensors track cutting forces, which increase with the
progression of wear, and temperature sensors record thermal 5) Tool wear prognostics: The Remaining Useful Life (RUL)
changes, reflecting friction and possible deterioration. The Estimation within the Tool Wear and Fault Diagnosis and
system gathers time-series data (continuous data) or Prognostics (TWFD&P) system is predicting the time
multivariate datasets integrating force, temperature, and sound remaining until a tool fails by forecasting wear development in
for holistic analysis. clusters. The system employs trend-based prediction, whereby
it tracks the transition from one wear cluster to another, and
2) Data preprocessing: For enhancing the precision of Tool time-to-failure estimation via clustering-based regression
Wear and Fault Diagnosis and Prognostics (TWFD&P) with models. Some of the key prognostic models are K-means with
AI, various preprocessing operations are performed. Noise regression, where the output of clustering is used as features
reduction is achieved through filtering methods such as low- for a regression model (e.g., Linear Regression) to estimate
pass filters and wavelet denoising in order to eliminate RUL. Also, time series forecasting methods like ARIMA and
unwanted noise in sensor readings. The data are subsequently LSTM are used to forecast future wear stages based on
scaled and normalized to standardization with techniques like clustering patterns, allowing for effective and proactive
Min-Max scaling or Z-score normalization to standardize it for maintenance planning.
the purpose of clustering. Subsequently, feature extraction is
carried out based on both time-domain (e.g., mean, standard 6) Visualization and reporting: The clustering outcomes in
deviation, skewness) and frequency-domain features (e.g., the Tool Wear and Fault Diagnosis and Prognostics
FFT – Fast Fourier Transform) in order to find frequency (TWFD&P) system are shown through scatter plots or 3D
spikes resulting from wear. Finally, dimensionality reduction visualizations, highlighting clear wear states and clusters of
methods such as PCA (Principal Component Analysis) is faults. Wear trend graphs represent the steady evolution
employed to reduce the high-dimensional data into lower through various wear clusters over time. The system creates
dimensions while retaining the most informative features, detailed fault logs based on clustering outcomes, including
improving the efficiency of the clustering process. insights into wear development and patterns of faults. It
assigns wear severity ratings from No wear to Minor wear,
3) Clustering algorithms: Clustering classifies sensor data Moderate wear, severe wear, and eventually critical failure.
into groups of similarity in the hope of creating clusters The system also estimates the Remaining Useful Life (RUL)
corresponding to various wear or fault conditions. Different through a study of cluster-to-cluster transition rate to facilitate
clustering techniques are employed for that purpose. K-means precise time-to-failure predictions for efficient predictive
clustering divides the data into `k` clusters based on wear- maintenance.
related feature proximity, essentially discovering wear patterns
and classifying them into low-wear, moderate-wear, and III. LITERATURE REVIEW
severe-wear conditions. DBSCAN (Density-Based Spatial
Recently, tool wear and fault diagnosis based on AI
Clustering of Applications with Noise) is appropriate for noisy
systems have gained increased attention in the manufacturing
real-world sensor readings since it clusters dense areas of fault
and condition-based predictive maintenance fields. Engineers
patterns and also labels the noise points as outliers.
have tried enhancing the reliability and accuracy of the tool
Hierarchical clustering creates a tree-like structure of clusters
condition monitoring through various ML and DL strategies.
and is best for visualization of wear stages, particularly for
Zhao et al. (2019) employed Convolutional Neural Networks
small to medium-sized datasets. Finally, Gaussian Mixture
(CNN) to diagnose the tool wear through the way of images
Model (GMM) may be assigned to give probabilities for the
with the satisfactory accuracy and efficiency in detecting
instances within other clusters, thereby making it acceptable
visual wear. Wang et al. (2020) employed Long Short-Term
for incrementally detecting the transition of wear.
Memory (LSTM) networks to predict the Remaining Useful
4) Fault diagnosis: Cluster labelling, labels every cluster with Life (RUL) of cutting tools from time-series sensor data with
a corresponding fault state or wear level from previous data. In improved prognostic performance. Zhang et al. (2021) also
fault detection, new readings are mapped onto the nearest suggested an unsupervised K-means and Principal Component
cluster for real-time fault detection. For example, Cluster 1 is Analysis (PCA)-based clustering model for anomaly detection
© 2025 IRJIET All Rights Reserved www.irjiet.com 350
International Research Journal of Innovations in Engineering and Technology (IRJIET)
ISSN (online): 2581-3048
Volume 9, Special Issue INSPIRE’25, pp 349-354, April-2025
https://doi.org/10.47001/IRJIET/2025.INSPIRE56
International Conference on Sustainable Practices and Innovations in Research and Engineering (INSPIRE'25)
and wear pattern classification. Innovations have also utilized B. Sensor-Based Diagnosis and Prognosis:
hybrid schemes that combine Random Forest (RF) and
Support Vector Machines (SVM) for enhancing the accuracy Vibration monitoring identifies unusual vibrations of the
of fault classification. Still, current models are marred with tools that signal wear or failure, acoustic emission (AE)
issues related to noisy data handling, adjustments for changing screens high-frequency stress waves produced due to crack
machining conditions, and precise RUL prediction. Thus, the formation, thermal measurement detects temperature variation
introduced system adopts multi-sensor data fusion and due to wear caused by friction, and force and torque
complex DL models for enhanced diagnostic precision, fault measurements monitor variations in cutting force and torque
diagnosis automation, and optimization of maintenance patterns indicating tool degradation. These techniques do have
prediction policies. their weaknesses, though, as they fail to deal with intricate,
non-linear wear processes and are incapable of providing
IV. EXISTING METHODOLOGY correct predictions of remaining useful life (RUL) of the tool.
In the current system, conventional condition monitoring V. PROPOSED METHODOLOGY
methods are applied for fault diagnosis and tool wear. Rule-
based models, manual thresholds, and simple statistical The AI-powered system offers a smarter and more
analysis are the basis of such systems, and they lack precision reliable solution by using Machine Learning (ML) and Deep
and flexibility. Learning (DL) models to monitor, diagnose, and predict tool
wear and faults in real-time.
A. Methodologies in the Existing System:
A. Data Collection and Preprocessing:
1) Manual Inspection & Monitoring: Periodic physical
inspection of tools for wear and faults is a traditional 1) Multi-Sensor Integration: The system receives real-time
maintenance practice. However, it is time-consuming, labour signals from several sensors. The system receives real-time
intensive, and prone to human error, making it inefficient and signals from several sensors, such as vibration, temperature,
less reliable for accurately detecting tool degradation. force, and sound signals, to track tool conditions. It also
receives images to analyse visual wear so that full-fledged and
2) Threshold-Based Methods: The traditional system uses accurate fault detection can be achieved.
fixed thresholds for force, vibration, or temperature to identify
faults. However, it is ineffective for detecting gradual wear or 2) Preprocessing Techniques: Noise and outliers in raw data
complex fault patterns, as it relies on predefined limits rather are removed by filtering to provide cleaner and more reliable
than adaptive analysis. Additionally, it lacks the flexibility to inputs for analysis. Feature extraction focuses on detecting and
accommodate varying machining conditions, making it less extracting the most important time-domain and frequency-
reliable in dynamic manufacturing environments. domain features like Root Mean Square (RMS), kurtosis, and
spectral entropy that represent tool-wear patterns. Finally,
3) Statistical and Rule-Based Approaches: Statistical normalization transforms the data into a similar range,
Process Control (SPC) analyses variations in machining data improving model performance and stability by avoiding over-
to detect anomalies by monitoring the process stability and reliance of some of the features during learning.
identifying deviations from expected patterns. It uses
predefined rules to trigger fault alarms when abnormal B. AI-Powered Diagnostic Models:
variations occur. However, SPC struggles with dynamic and
1) Supervised Learning Methods: Random Forest (RF)
non-linear tool wear patterns, making it less effective in
categorizes the wear level into low, medium, and severe
accurately detecting complex or evolving faults.
categories based on historical labeled data analysis. Support
4) Machine Learning with Supervised Learning: The Vector Machines (SVM) are utilized to identify faults by
system employs sensor data labeled by AI to train recognizing patterns in the sensor signals, thus separating
classification models including Support Vector Machines normal and faulty tool conditions. Artificial Neural Networks
(SVM) and Random Forest. This requires big datasets of (ANN) further strengthen the ability of the system to learn
labeled data, which tend to be costly and time-consuming to complex correlations between tool conditions and input
obtain. The system is also not very good at generalizing when features to ensure correct fault diagnosis and wear forecasting.
it sees new or unseen wear conditions, hence tending to fail
2) Unsupervised Learning Methods (Clustering): K-means
when faced with unexpected faults.
clustering groups tool conditions by feature similarity,
accurately classifying different wear levels. Abnormal tool
© 2025 IRJIET All Rights Reserved www.irjiet.com 351
International Research Journal of Innovations in Engineering and Technology (IRJIET)
ISSN (online): 2581-3048
Volume 9, Special Issue INSPIRE’25, pp 349-354, April-2025
https://doi.org/10.47001/IRJIET/2025.INSPIRE56
International Conference on Sustainable Practices and Innovations in Research and Engineering (INSPIRE'25)
behaviour is identified through the use of DBSCAN (Density- predictive maintenance, lessening sudden downtimes and
Based Spatial Clustering), where possible faults are boosting efficiency of operation.
highlighted through outlier detection in the data. Principal
Component Analysis (PCA) too lowers the dataset VII. CONCLUSION
dimensionality while retaining significant wear-related
The fault diagnosis and prognostics and tool wear based
information. This makes the diagnostic models more effective
unsupervised learning AI tool presents an efficient and
and efficient.
powerful solution to monitor the tool health and predict tool
C. Prognostic Models: health throughout the manufacturing process. Utilizing the
clustering algorithms of K-means, DBSCAN, and PCA, the
Deep learning algorithms are central to AI-based tool system has the capability to identify the different tool wear
wear and fault diagnosis systems through enabling the precise patterns automatically, find the abnormalities, and classify
and automated analysis. Convolutional Neural Networks diagnose similar fault behaviours without needing any labeled
(CNN) is employed in analysing images of tool surfaces to data. This enables real-time fault detection and accurate
read wear patterns and automate visual inspection. Recurrent estimation of Remaining Useful Life (RUL), enhancing
Neural Networks (RNN), especially Long Short-Term predictive maintenance. The unsupervised approach also
Memory (LSTM) networks, forecast the Remaining Useful adapts to different operating conditions, which is flexible and
Life (RUL) of tools by analysing time-series sensor scalable for industrial use. Overall, this system minimizes
measurements, precisely capturing temporal dependencies. downtime, enhances tool life, and enhances manufacturing
Moreover, autoencoders are used for anomaly detection to efficiency by enabling proactive, predominantly
detect abnormal patterns of wear and are thus extremely useful manufacturing of quality products in the industrial world.
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Volume 9, Special Issue INSPIRE’25, pp 349-354, April-2025
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International Research Journal of Innovations in Engineering and Technology (IRJIET)
ISSN (online): 2581-3048
Volume 9, Special Issue INSPIRE’25, pp 349-354, April-2025
https://doi.org/10.47001/IRJIET/2025.INSPIRE56
International Conference on Sustainable Practices and Innovations in Research and Engineering (INSPIRE'25)
Citation of this Article:
M. Amareswara Kumar, G. Jayasai Karthik, D. Hussain Basha, S. Ashraf, P. Ramesh, O. Yogeeswar, & K. Chaitanya. (2025).
Tool Wear and Fault Diagnosis and Prognostics Powered by AI. In proceeding of International Conference on Sustainable
Practices and Innovations in Research and Engineering (INSPIRE'25), published by IRJIET, Volume 9, Special Issue of
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