AUTOMATIC CUTTING TOOL FAULT DETECTION USING WAVELET ANALYSIS AND AN ARTIFICIAL NEURAL NETWORK (ANN)

Nasser Al-Mushifri, Khalid F. Abdulraheem, Waleed Abdul-Karim

ABSTRACT
In this investigation the cutting fault detection techniques have been developed based on the wavelet analysis and artificial neural network (ANN) as automatic cutting tool fault detection and classification. Two experimental works have been employed to capture the vibration signals for analysis .In both experiments, the turning lathe machine is used with high carbon steel tip cutting tool and mild steel material as work piece. In the first experiment, the vibration measuring device (vibro-60) is used to collect and analysis the vibration acceleration signals. The time domain statistics with different wear conditions have been calculated using MATLAB software. The cutting condition parameters are kept constant and the wear level is changed for both experiments. In the second experiment the Data Acquisition system (DAQ) with LABVIEW software is used to capture the vibration signals for cutting tool with different wear conditions. The captured vibrations data are analyzed using continuous wavelet transform (CWT) with Morlet wavelet and Daubechies wavelet as a base function. In general, the CWT coefficient is used to generate the inputs features to ANN for automatic tool condition classification, with two outputs (0, 1) for healthy and (1, 0) for faulty. The results show the effectiveness of the combed WT and ANN for automatic classification of tool wear conditions with high success rate.

INTRODUCTION The quality of the products is very important for customers because it is the quality that influences the degree of satisfaction of the consumers during usage of the goods procured, therefore the manufacturing, industrial and production unit should monitor the conditions of machines because the production is connected to a good health of the machine. So, condition monitoring is important for increasing machinery availability, improving manufacturing process, productivity and reliability, and reducing maintenance costs. The most important thing an investor is concerned is profit and how to save on the cost of production under the market pressure and companies compotation. An efficient condition monitoring scheme is capable of providing warnings and predicting faults at early stages. In this work the predictive or condition-based maintenance is applied based on the wear condition. This type is useful to monitor the condition of the cutting tool of a lathe machine which uses a specific technique which is cutting tool vibration signal. It can be used to detect

the signal of the cutting tool faults and analyses by using the time domain statistics and wavelet analysis as feature extraction. The extracted WT analysed parameter to be fed as inputs features to an artificial neural network (ANN) for fault detection and classification. The cutting fault detection techniques have been developed based on the wavelet analysis and ANN as automatic cutting tool fault detection and classification. Two experimental works have been employed to capture the vibration signals for analysis with different measuring intervals. The turning lathe machine is used with high carbon steel tip cutting tool and mild steel material as work piece. The cutting condition parameters are kept constant (speed 280 rpm, feed rate 0.1 mm/rev, depth of cut 0.5 mm and the direction of sensor is vertical) and the wear levels (0.0mm, 0.2mm , 0.4mm and 0.6mm) are changed for both experiments. Techniques for cutting tool condition monitoring can be grouped into two main categories, direct sensing and indirect sensing techniques. D.E. Dimla Sr. (2000) has reported that direct methods are less beneficial than indirect methods because the cutting area is largely inaccessible, and therefore on-line monitoring cannot be carried out while the tool is engaged in -process cutting. The direct methods use these technologies: touching trigger probes, optical, radioactive, proximity sensors and electrical resistance measurement techniques (I.N. Tansel 1992). Furthermore, indirect methods are widely used in cutting tool condition monitoring and as fault detection. They are used in different techniques such as cutting forces, acoustic emission, temperature, vibration, spindle motor current and torque (S. S. Abuthakeer 2011). However, vibration measurement for machinery condition monitoring is easy, less costly and yields a great deal of information that can be used to monitor the relative motion between the tool tip and the work piece for precision of the cutting operation (Qiao Sun 2005). Issam Abu-Mahfouz et. al. (2003) have reported that vibration analysis is widely accepted as a tool to monitor the operating conditions of a machine as it is nondestructive, reliable and permits continuous monitoring without intervening with the process. This study has demonstrated tool condition monitoring approach in turning operation based on the vibration signal collected because of the availability, low cost, large information data, nondestructive, reliable and permits continuous monitoring for on-line monitoring. This use is easily replaceable and very costeffective accelerometer.

Wavelet analysis
A short oscillating function which contains both the analysis function and the window is known as a wavelet. Wavelets are applied to transform the signal under examination into another representation which presents the signal information in a more amenable form .This type of transformation is known as Wavelet Transform (WT) which is converting the function or signal into another form to make certain features of the original signal more useful to investigate. There are five categories of wavelet transform in TCM: timefrequency analysis of machining signal, feature extraction, signals denoising, singularity analysis for tool state 38 estimation, and density estimation for tool wear classification according to its multiresolution, sparsity and localization properties ( Zhu Kunpeng 2009). The wavelet method overcomes the limitation of FT, by using a multi-resolution technics (time & frequency).

Hence, it has the ability to examine the signal simultaneously in time and frequency with a flexible mathematical foundation. Time information is obtained by shifting the wavelet over the signal. The frequencies are changed by contraction and dilatation of the wavelet function. The wavelet analysis is more sensitive and trustable than the Fourier analysis for recognizing the tool wear states in turning (W.Gong, 1997). Joseph Fourier in 1800 shows the ability of superpose sines and cosines to represent other functions. The wavelets were first mentioned by Alfred Haar in 1909. It can be moved at various locations on the signal and also it can be squeezed to different scales. There are some requirements for the wavelet, which are: it must have finite energy, based on Fourier transform, the wavelet must have zero mean and for complex wavelets the Fourier transform must be both real and vanish for negative frequencies. To make the wavelet of chosen mother wavelet more flexible, two basic manipulations are applied which are stretch or squeeze it (dilation) and move it (translation). The dilation of the wavelet is governed by the dilation parameter a. The movement of the wavelet along the time axis is governed by the translation parameter b. These shifted and dilated versions of the mother wavelet (t) are denoted by [(t b)/a]. The wavelet represented by (Paul S. Addison, 2002): ()

) is used to ensure energy preservation.

(1)

Where, the factor

The sum over all time of the signal multiplied by scaled and shifted versions of the wavelet function is called the continuous wavelet transform (CWT). Continuous wavelet transforms are recognized as effective tools for both stationary and non-stationary signals. Based on the equation (3 9) the CWT given as: ( ) () () (2) X (t) is the signal and the

Where, ( ) is the continuous wavelet transform (CWT), superscript asterisk '*' stands for the complex conjugate. It can be expressed in more compact form as an inner product:

(3)

The windowing techniques with variable-size regions in wavelet analysis can be overcome the limitations of the STFT. Wavelet analysis allows the use of shorter time intervals where more precise high frequency information is desirable and long regions for low frequency information. Sometimes the wavelet is irregular and asymmetric waveform of effectively limited duration (average value zero), so the varieties of wavelets (Wavelet Families) are exist, and an analyst can choose from the wavelet families that suits his application best. This project focuses on Daubechies wavelets (db10) and Morlet wavelet (morl) as basis function based on the role of features extraction, because they are more similar

characteristics to the extracted signals. The morl wavelet is known by the following Equation (Semmlow, 2004). Figure 1 shows the morl wavelet. ( ) ( ) (4)

Figure 1 Morlet wavelet.

The names of Daubechies family wavelets are signed db N (N is the order) as Figure 2 shows the db 10 wavelet. The Daubechies wavelet is defined as given in equation (5) (Daniel T.L. Lee, 2004). ( ) ( ) = (-1) k k +1 , If N= 1, then 0= = 1 (5)

Where, (t) is scaling function and

Figure 2 Daubechies wavelet db 10

ARTIFICIAL NEURAL NETWORK (ANN) The idea of Artificial Neural Network (ANN) is, creating a computing system that simulates the biological neural systems of the human brain. The artificial neural network is particularly useful in the modeling of nonlinear mapping, and also in the recognition of distinctive features from chaotic input data even if it is not complete. The behavior of ANN modifies in response to its environment. The inputs will self-adjust while a set of them are given to the network to produce consistent responses through a process called learning. The learning process can change the weights systematically in order to achieve some desired results for a given set of inputs. The types of learning are, supervised and unsupervised; the supervised has been selected based on the environment knowing. The popular algorithm related to the supervised learning is known as the Back-Propagation. The construction of ANN involves the determination of the network properties depending on the network topology (connectivity), the type of connections, the order of connections, and the weight range. Moreover, it determines the node properties like the activation range and the activation function. Also, in dynamic system the ANN determines weight initialization scheme, the activation calculating formula and the learning rule. A large number of researchers presented application of neural network models in Tool Condition Monitoring (TCM) and classification of tool wear. Artificial neural network (ANN) is useful as online prediction of tool wear based on back propagation network (R R Srikant, 2011). The multilayer feed-forward neural network with a back propagation (FFBP) training algorithm is successful in TCM as tool fault detection and classification (Issam Abu-Mahfouz 2003). In this project the ANN is used as fault detaction and wear condition classification based on Multilayer feed-forward with back propagation. To classify and quantify the fault of cutting tool, neural network is used with signal analysis techniques. Neural network method for automatically classifying the machine condition from the vibration time series have used by McCormick and Nandi (1979). Artificial neural network contain many connected neurons, which work as receiver for the impulses from input or other neurons. These neurons transform the input by giving the outcome to the output or other neurons. Also, ANN consists of different layers of connected neurons, which receive the input from the previous layer and transfer the output to the succeeding layer. Figure 3 shows the model of a neuron, where the inputs are forwarded to the neuron and multiplied by their synaptic weights. Then, the outcome is forwarded to sum in summing junction and it is activated by the activation function. The inputs of the activation function are affected by the bias (bi), so it will increase if positive and decrease in the case of negative. Finally, the output will be given. The learning and storing of the knowledge will be possible by this model of the ANN.

Figure 3 The model of a neuron Typically, in neural network architectures two types of layers are organized in the shape of a layered neural network. There are the signal-layer feed-forward perceptron (SLP) neural network and the feed-forward multilayer perceptron (MLP) ANN. The arrangement of neurons in each of the layers is entirely dependent on the user, hence they have the ability to represent a large range of output and input patterns. The Figure 4 shows the limitations in the range of functions or processes that they can represent in signal-layer feed-forward (SLP) neural network. However, the feed-forward multilayer perceptron (MLP) neural network is selected in this study; because it has a wide range of processes and more powerful representation capacity which can be achieved by using more than one layer, as shown in Figure 4 .

Figure 4 Typical diagram of a single-layer perceptron

Figure 5 Typical diagram of multi-layered feed-forward ANN

EXPERIMENTAL SETUP In This study the experimental work demonstrates the tool condition monitoring approach in turning operation based on the vibration monitoring. This experiment was conducted in the Workshop in Caledonian College of Engineering (CCE) using (TM-35) lathe machine. However, two experiments have been applied to monitor the tool wear based on vibration signals collected from two different measuring devices. These experiments work with same procedure and parameters of the cutting conditions, which are speed 280 rpm, feed rate 0.1 mm/rev, depth of cut 0.5 mm and the direction of sensor is vertical. Moreover, all these experiments have been setup based on the different wear conditions, which are healthy tool, 0.2mm, 0.4mm and 0.6mm wear levels. Preparing For the Experiments This experimental work has a small preparation which can create the wear levels at the tip of carbide inserts. In this experiment first, the carbide inserts is fixed on the tool holder and the grinding wheel is gagged at the lathe machine as shown in Figure 6 (a). Then, the lathe machine has to be adjusted to make wear at the cutting tool using the grinding wheel with speed of 450 rpm. When the lathe machine is adjusted to a depth of cut 0.2 mm the wear is created about 0.2mm wear level. Finally, the wear at carbide insert tips is measured using the microscope. The same procedure is used to create the 0.4mm and 0.6 wear level. Figure 6 shows an example of the process of creating wear levels.

Figure 6 An example of the process of creating wear levels, (a) use of grading wheel, (b) the wear created in the tip of carbide insert and (b) the microscope. Experiment ( I )

Experiment (I) is applied to measure the vibration of the cutting operation using Predictive Machine VIBROTEST 60 to handle the vibration analyzer and data collector. The vibration signals are measured using vibro (60) device for different wear conditions, in which health tool, 0.2 mm 0.4 and 0.6 mm wears. In this experiment the workpiece and cutting tool is fixed at the lathe machine and the distance between the work piece and the cutting tool is adjusted. First, the new cutting tool with (0.0mm) wear is employed with the work piece and the direction of the accelerometer sensor (coated by aluminum coil for safety) is vertical as show in the Figure 7.

Figure 7 The adjusting workpiece and cutting tool at the lathe machine Also, the acceleration sensor has to be connected between the VIBROTEST 60 and the cutting tool holder using AC-437 Cable to collect the signals. While the lathe machine rotates and the cutting process starts, the acceleration sensor sends the signals to VIBROTEST 60. After that, the data will be saved in PCMCIA card, which can be transferred to a PC with a card reader and XMS program. Finally, the selective data is analyzed using MATLAB. The same procedure is applied to the other cutting tools with 0.2 mm, 0.4 mm and 0.6 mm wear levels. Figure 8 shows the experiment (I) setup.

Figure 8 The experimental (I) setup Experiment (II)

In this experiment the vibration signals are captured by data acquisition card from National Instruments (DAQ Card) with LABVIEW software. However, the cutting condition is stable for both experiments, but with different accelerometer and connecting cables. The experiment (II) setup is same as the experiment (I), but this experiment is directly connected to a PC with a data acquisition card (DAQ card) (Type SHC 68-68-EPM) and LABVIEW software and this experimental works with 16000 sampling rate. In this experiment the vibration signals of the cutting tool with different wear conditions (healthy, 0.2mm, 0.4mm and 0.6mm) are captured by the accelerometer sensor to shift and convert these signals from analogue to digital form using a PC with data acquisition card from National Instruments (DAQ Card) and LABVIEW software. Figure 9 shows the experimental (II) setup.

Figure 9 the experimental (II) setup Finally, the LABVIEW shows the features of the vibration signals as time domain and frequency domain. Also, for further analyzing the suitable vibration signals the MATLAB is used to analyses the signals based on Wavelet analysis and ANN as automatic cutting tool fault detection and classification.

THE EXPERIMENTAL RESULTS AND DISCUSSIONS

This section presents the experimental results and discussion of the test vibration measuring device (vibro 60) and based on acceleration signals and time domain statistics. Also, it shows the results and discussion of Data Acquisition system (DAQ) with LABVIEW software using (CWT). Finally, it illustrates Automatic fault detection and classification of cutting tool using ANN. PART I: USE THE TEST VIBRATION MEASURING DEVICE (VIBRO 60) The vibration measuring device (vibro-60) is used to select the best vibration signals to show the results based on the acceleration signals and time domain statistics with different wear condition using MATLAB software. Acceleration signals Figure 10 shows results show the different vibration signals acceleration from vibro 60 for new tool (healthy) and different wears at speed 280 rpm, feed rate 0.1 mm/rev, depth of cut 0.5mm and the direction of sensor is vertical. These accelerations show the ability to recognize between the healthy condition and faulty condition of the cutting tool. All the given graphs are plotted based on time duration of 17 sec.
4 New tool 3
Accelartaion(g)
Accelaration(g)

4 wear 0.2 3

8 10 Time(sec)

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8 10 Time(sec)

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(a)
4 wear 0.4 3
Accelaration(g)

(b)
4 wear 0.6 3
Accelaration(g)

8 10 Time(sec)

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8 10 Time(sec)

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(c)

(d)

Figure 10 Acceleration form for (a) new tool, (b) 0.2 mm wear,(c) 0.4 mm wear and (d) 0.6 mm wear.

Time domain statistics

The following results are demonstrated a comparative graphs of time domain statistics for healthy tool and different wears condition. Time domain parameters show different features of the vibration signal to recognize between the healthy condition and different wears condition of the cutting tool. Figure 11 shows the effectiveness of the parameters of time domain namely (Peak, RMS, Crest Factor, Kurtosis, Impulse Factor and Shape Factor) on the wear conditions.

0.6 0.5
Peak

0.25 0.2
RMS

0.4 0.3 0.2 0.1 0 0 0.2 Tool wear (mm) 0.4 0.6

0.15 0.1 0.05 0 0 0.2 Tool wear (mm) 0.4 0.6

(a)
3.2 3
Crest factor

(b)
7 6 5
Kurtosis

4 3 2 1

2.8 2.6

0.2 Tool wear (mm)

0.4

0.6

0 0

0.2 Tool wear (mm)

0.4

0.6

(c)
2 1.5 1 0.5 0 0
Shape factor

(d)
0.8 0.6

Impulse factor

0.4 0.2 0 0

0.2 Tool wear (mm)

0.4

0.6

0.2 Tool wear (mm)

0.4

0.6

(e)

(f)

Figure 11 (a-f) Time domain features for deferent wear condition: (a) Peak, (b) RMS, (c) Crest Factor, (d) Kurtosis, (e) Impulse Factor and (f) Shape Factor.

The peak level is generally increasing as the wear of the tool increase Figure 11 (a). This reflects the increasing in the overall vibration level as shown in Figure 10.The RMS level (root-mean-square) for wear condition Figure 11 (b) shows that the RMS values increase as the wear of the tool increase from healthy to 0.6 mm wear. This because the average vibration amplitude (mean) and the effect of spurious peaks increase by developing the tool wears. Figures 11 (c, d) shows the crest factor and the kurtosis factor decrease as the tool wear increase. They are decreasing with progressive failure of the cutting tool because the RMS level generally increases. Moreover, the crest factor expresses that the instrument has the capability of correct measurement how much distorted waveform. And, kurtosis is any measure of the "peakedness" of the probability distribution of a real-valued random variable. So, the kurtosis is high for healthy tool because the signal sharpness is large (sharp tool) and then signals became more noisy (i.e. the values distributed over wide raise) as the wear increase. The impulse factor and shape factor for cutting tool condition Figure 11 (e, f) show that as the tool wear increase the values of impulse factor and the shape factor increase. However, the impulse factor is referring to control the disorder of the data. And, the shape factor is referring to how much the tool will deform when pressure is applied to it. So, the shape factor is increasing during the wear increasing. PART II: USING DATA ACQUISITION SYSTEM (DAQ) WITH LABVIEW SOFTWARE This section presents the results of applying the Continuous Wavelet Transform (CWT) for cutting tool with different wear condition. The CWT is used also as features extraction method for generate the inputs feature to ANN. Morlet wavelet (morl) and Daubechies Wavelets (db 10) has been used as a mother wavelet function while obtains the CWT coefficients. Continuous Wavelet Transform (CWT) Analysis Figure 12 shows the results of wavelet analysis for different vibration signals captured by DAQ for new tool (healthy) and different wears at speed 280 rpm, feed rate 0.1 mm/rev, depth of cut 0.5mm and the direction of sensor is vertical. In Figure 12 the results are demonstrated comparative graphs of kurtosis factor of 20 wavelet coefficients for healthy tool and (0.2, 0.4, 0.6) mm wear, respectively. These graphs present the effectiveness of kurtosis factor in wavelet scale, and then compare it to histograms of healthy tool and each different wears. This technique shows the ability to recognize between the healthy condition and faulty condition.

60

50

wavelet kurtosis

Healthy 0.2 wear 0.4 wear 0.6 wear

40

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scale
Figure 12 The Kurtosis distribution for wavelet transform scales [healthy tool and (0.2, 0.4, 0.6) mm wear] The Kurtosis distribution of wavelet transform scales Figure 12 presents that the kurtosis of healthy tool is higher than the fault condition. As the sharp tool produces a signal with less randomness and as the wear progress the randomness of the signal is increased that produce a flat signal distribution as a result the kurtosis value will decrease. This clear in the histograms for healthy tool and (0.2, 0.4, 0.6) mm wears shown in Figure 13 (a-e).

Figure 13 (a) The wavelet kurtosis by the wear condition and (b-e) the histograms of healthy tool and (0.2, 0.4, 0.6) mm wear.

To change the wavelet scale to frequency (Hz), this equation is applied: Fa = Fc / a . Where, a is a scale, is the sampling period (0.1), Fc is the center frequency of a wavelet in Hz and Fa is the pseudo-frequency corresponding to the scale a in Hz. In the selected signal was in 280 rpm, so the frequency equal to (280/60) 4.6 Hz. Figure 14 shows the kurtosis distribution of wavelet transform at frequency (Hz) for healthy tool and (0.2, 0.4, 0.6) mm wear, respectively.
60

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Healthy 0.2 wear 0.4 wear 0.6 wear

wavelet kurtosis

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frequency (Hz)

Figure 14 The Kurtosis distribution for wavelet transform at frequency (Hz) [healthy tool and (0.2, 0.4, 0.6) mm wear]

The wavelet kurtosis decrease when tool wear increase as shown in above Figure 14 this is corresponding to frequency in hertz ( ). That is referring to the damping of the cutting tool increase as result of increasing in the wear. When the wear increase the contact area of the cutting tool with the workpiece also increase. That makes the friction increase, so the damping increase and the machine frequency decrease for lately the peak at 4.06 Hz for healthy tool and shifted to 1.35 Hz for 0.2 mm wear, again decreased for 0.4 and 0.6 mm wear. All that is presented in this equation: where, d is damped frequency, n is the undamped angular frequency and is damping ratio which increase by increase tool wear. AUTOMATIC FAULT DETECTION AND CLASSIFICATION OF CUTTING TOOL USING ANN Automatic fault detection and classification of cutting tool condition using the features of wavelet and Artificial Neural Network (ANN) model is proposed for this project. By using The Artificial Neural Network (ANN) to classify the tool wear conditions the model of ANN is created based on feed-forward Multi-Layer Perceptron (MLP) and Back Propagation. The result features (peak, RMS, crest factor, kurtosis, shape factor and impulse factor) healthy condition and wear condition are feed to ANN to classify the wear condition. The signal consists of 38400 data for each condition (wear & healthy) and then 10 coefficients are taken for each of these wear conditions. To build the ANN model six features are extracted from 10 coefficients for each condition, then the values divided into 30 (5x6) values for

training and 30 values (5x6) for testing as shows in Table 3 and Table 4, respectively. The healthy condition is normalized as (0 1) and wear condition as (1 0) for training targets. Table 3 Training values feed to ANN Condition RMS 0.4668 0.4041 Healthy 0.3559 0.3279 Training 0.4024 2.0584 2.3546 Wear 2.3849 2.1151 2.1816 Kurtosis 11.1281 7.2317 7.6381 3.6604 6.3357 4.6147 3.4431 4.6438 3.3395 4.8249 Peak 3.8155 2.6389 2.5896 1.6874 2.4941 11.3996 9.4807 14.0839 8.3399 13.9964 Crest 8.1746 6.5300 7.2761 5.1461 6.1978 5.538 4.0266 5.9054 3.943 6.4157 Impulse 1.5383 0.8989 0.9182 0.5828 0.9593 18.0085 17.4506 26.0475 13.8874 23.9821 Shape 0.1882 0.1377 0.1262 0.1132 0.1548 3.2518 4.3339 4.4108 3.522 3.738 Target 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1 0 0 0 0 0

Table 4 Testing values feed to ANN Condition RMS Kurtosis Peak Crest 9.7217 4.5816 4.826 5.0959 4.9061 Impulse 1.4858 0.4926 0.4944 0.5459 0.4446 Shape 0.1528 0.1075 0.1024 0.1071 0.0906

0.4134 12.8182 4.0192 0.3218 3.9022 Healthy 0.3162 3.9536 0.3274 4.339 Testing 0.2901 3.5146 1.4742 1.5259 1.6683 1.4233

2.7586 18.9119 27.5982 10.0046 52.6953 5.2671 2.4656 5.026 Wear 2.6058 9.7085 2.3226 3.511 2.6525 8.3905 15.5254 6.2967 25.6753 9.8532 8.6374 21.069 3.7189 7.9431 29.5224 4.6885 50.4149 5.1166 15.7201 4.2271 42.2863 5.3237

The ANN model is created using input layer with six nodes (extracted features), two hidden layers consist five nodes for each and output layer as shown in Figure 15. Back Propagation is applied to minimize the Mean Square Error (MSE) between the ANN outputs and the desired target values.

Figure 15 The model of ANN In this model two stages are applied which are training stage and testing stage. It is trained with 10E-10 training goal (MSE), 0.52044 training rate, with six attribute (features) and the maximum No. of iteration (epochs) of 1000 are selected. Figure 16 shows the result of training process, in which it reached the desired goal stopping criteria after 27 epochs.

Figure 16 Training process of ANN

Figure 17 presents the ANN parameters and the training stage performance in which the ANN performance is shown as 98% success rate.

Figure 17 ANN parameters and the training stage performance The regression curve for both training targets and the ANN output is shown in Figure 18, a good correlation between the both can be concluded. The results for ANN classification for tool wear condition shown success rate based on the given six features.

Figure 18 The regression curve for both training targets and the ANN output

CONCLUSIONS Based on the obtained results the overall conclusion can be summarized as follow: The acceleration of vibration signals and time domain statistic shows the ability to recognize the tool wear condition.

 Kurtosis Factor proved to be more accurate fault detection parameter comparing to other wavelet parameters (Peak, RMS, crest factor, Impulse Factor and shape factor). For more accurate fault detection of the cutting tool a new techniques has been developed, which are wavelet kurtosis factor and the histograms throughout using Morlet wavelet and Daubechies Wavelets as a mother wavelet function (similarity with the extracted fault pulses shape). This technique shows the ability to recognize between the healthy and wear conditions. The wavelet analysis is selected for cutting tool vibration signal features extraction. The advantage of wavelet analysis is proven as a multi resolution, scaling and shifting of the wavelet through the vibrational signal. For high performance of the extracted wavelet features; the features are normalized between 0 and 1 in order to be the inputs in ANN. The ANN model based on supervised learning capability of Multi-Layer Perceptron (MLP) and Back Propagation has shown effectiveness to be as automatic cutting tool fault detection and classification, as proven that the training process has been reached the desired goal stopping criteria after 27 epochs. And the ANN performance is shown as 98% success rate. This project is proved the successful correlation between the wavelet transform (WT) and the tool wear condition based on the obtained results.

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