Tool Wear Detection in Milling Using Convolutional Neural Networks and Audible Sound Signals

Timely tool wear detection has been an important target for the metal cutting industry for decades because of its significance for part quality and production cost control. With the shift toward intelligent and sustainable manufacturing, reliable tool-condition monitoring has become even more critical. One of the main challenges in sound-based tool wear monitoring is the presence of noise interference, instability and the highly volatile nature of machining acoustics, which complicates the extraction of meaningful features. In this study, a Convolutional Neural Network (CNN) model is proposed to classify tool wear conditions in milling operations using acoustic signals. Sound recordings were collected from tools at different wear stages under two cutting speeds, and Mel-Frequency Cepstral Coefficients (MFCCs) were extracted to obtain a compact representation of the short-term power spectrum. These MFCC matrices enabled the CNN to learn discriminative spectral patterns associated with wear. To evaluate model stability and reduce the effects of algorithmic randomness, training was repeated three times for each cutting speed. For the 520 rpm dataset, the model achieved an average validation accuracy of 96.85 ± 2.07%, while for the 635 rpm dataset it achieved 93.69 ± 2.07%. The results demonstrate the feasibility of using acoustic signals, despite inherent noise challenges, as a complementary approach for identifying suitable tool replacement intervals in milling.