Performance Analysis of Advanced Feature Extraction Methods for Manufacturing Defect Detection via Vibration Sensors in CNC Milling Machines

This study investigates the effectiveness of various feature extraction methods applied to vibration signals for the automatic detection of production defects in CNC (Computerised Numerical Control) milling machines. A dataset consisting of real-world data collected from CNC machines equipped with accelerometers was used. The objective of the study is to compare three main groups of techniques: time-domain analysis (TDA), frequency-domain analysis (FDA), and time–frequency-domain analysis (TFA). The findings indicate that basic TDA features lack the necessary sensitivity to accurately distinguish between Good Processing (GP) and Bad Processing (BP) states. Frequency-domain methods, such as the Fast Fourier Transform (FFT), median frequency calculation, and the Welch periodogram, provide better insights but still have limitations. The most effective results are obtained with TFA methods, particularly Empirical Mode Decomposition (EMD) and the Hilbert–Huang Transform (HHT), which reveal deeper signal characteristics. Following the feature optimisation studies, it was determined that a combination of four features—FMED, IMF2, IMF5 and WPT26—yielded the optimal performance, with an accuracy of 91.48%. The incorporation of a fifth feature resulted in information saturation within the model and did not improve performance. This study makes a novel contribution to literature by conducting an in-depth investigation into the most effective feature extraction and selection techniques for achieving robust discrimination between GP and BP productions using vibration signals in CNC milling processes. Conclusively, TFA features, supported by advanced signal processing, offer a strong basis for reliable, automated defect detection in CNC milling operations.