Existing studies have attempted to determine the tool chipping condition using the indirect method of data capture and intelligent analysis techniques considering machine parameters, and tool conditions using signal processing techniques. Due to the obstructive nature of the machining operation, however, it is daunting to use signal capturing to intelligently capture the condition of the tool as well as that of the workpiece. This study aimed to apply some advanced signal processing techniques to the vibration signals captured experimentally during machining operation for the decision making and analysis of tool and workpiece conditions. Vibration signals were captured during turning operations while using four (4) classes of tools, based on their flank wear. The signals were first pre-processed and decomposed using the Empirical Mode Decomposition (EMD) method. The Hilbert–Huang transform (HHT) was applied to the resulting IMFs obtained to compute the feature vectors used to classify the condition of the tool and workpiece. A total of 12 features, consisting of instantaneous properties such as instantaneous energy, instantaneous frequencies, and amplitudes, were obtained for data training and classification of tool conditions. To optimize the classification process, feature selection was performed using a genetic algorithm (GA) to reduce the number of features from 12 to 4 for data training and classification. The feature vectors were first trained for tool classification with a neural network scaled conjugate gradient (SCG) algorithm. The result showed that the model classification error was 0.102. Two other machine learning models, support vector machine (SVM) and K-Nearest Neighbors (KNN), were also implemented for classifying the tool conditions, from the feature vector, to determine the model that most accurately predicted the condition of the tool. To avoid bias and reduce misclassification errors, the k-fold cross-validation technique was applied with ‘k’ taken as 5 and 10. The computed feature vectors were used as inputs to train the machine learning model using both SVM and KNN models to classify the tool and workpiece condition during machining. The error loss of each model was evaluated and plotted to review the performance. The average overall error loss of 0.5031 was observed for the SVM model with 5-fold cross-validation, whereas the error loss of 0.0318 was observed for the KNN model with 5-fold cross-validation. The average overall error loss of 0.5009 was observed for the SVM model with 10-fold cross-validation when trained using the features selected by a genetic algorithm (GA), while the average overall error loss of 0.0343 was observed for the KNN model. The optimal performance of the SVM model was obtained when all features were used for the training, whereas the KNN model performed better when feature selection was implemented. The error losses of the models were evaluated to be less in KNN models, compared to SVM and SCG. The obtained results also showed that the developed KNN models performed 10 times better than the SVM model in predicting the tool condition from the captured vibration signal during the machining process.
