After processing the measured AE signals and implementing the strategies for suitable selection of features as described in Figure 5, an assessment of the sensitivity of the experimental cutting parameters to AE signal attributes was conducted. The measured AE signals were decomposed through six decompositions by five mother wavelets, so-called haar, db2, db10, sym8, and bior1.3. After selecting decomposed signals' attributes, a thorough assessment was performed by statistical examinations of the AE attributes. Figure 6 shows maximum R2 values for the most sensitive signal attributes belonging to the three most significant mother wavelets for approximate and detailed signal types. Based on Figure 6, the signal attribute "max" (for all three mother wavelets) has the highest R2 values among all five signal attributes within approximate signals and the lowest for detail signals, having the same R2 value of about 80% for both approximate and detail signals. It means that the "max" attribute does not have a wide difference for approximate and detail signals. All four other signal attributes, including rms, std, energy and entropy, have roughly the same R2 values for each of approximate and detail signals. However, the mentioned four attributes for detail signals have R2 values 20% more than approximate signals. In other words, the sensitivity of rms, std, energy, and entropy is 20% higher for detail signals. Therefore, regardless of the mother wavelet type, they were preferred over approximate signals for detecting the changes in machining operations when cutting parameters change. It should be noticed that for attribute "max" the second type of mother wavelet (db2) had a better performance. Due to page limit and long discussion needed, other examined AE signal attributes were not presented in Figure 6.
Figure 7 summarizes the R2 values of signal attributes, including rms, std, energy and entropy for all decompositions and all five mother wavelets studied. Different decompositions do not have the same capability to present sensitive features related to their various details and characteristics. Considering Figure 7, generally, it can be seen that decompositions 2 and 6 offer higher R2 values as compared to other decompositions. Thus, it can be easily understood that rms, std, energy, and entropy in the second and sixth decompositions of detail signals have acceptable sensitivity according to the introduced criteria. Besides, Figure 6 and Figure 7 show that R2 values obtained from the detail signals using the bior1.3, haar, and db2 mother wavelets had the best results, respectively. For further clarification, Table 6 presents the R2 and R2adj values of the rms, std, energy, and entropy attributes for decompositions 2 and 6, and bior1.3, haar, and db2 mother wavelets for the detail signals. Except for minor cases where their R2 was less than acceptable, the bior1.3, haar, and db2 mother wavelets in decompositions 2 and 6 provided sensitive attributes with acceptable accuracy.
Table 5. R2 and R2adj values of the rms, std, energy, and entropy features for decompositions 2 and 6, using the bior1.3, haar, and db2 mother wavelets
Table 5
R2 and R2adj values of the rms, std, energy, and entropy features for decompositions 2 and 6, using the bior1.3, haar, and db2 mother wavelets
R2 & R2adj
|
2nd Decomposition
|
6th Decomposition
|
rms
|
std
|
energy
|
entropy
|
rms
|
std
|
energy
|
entropy
|
R2
|
R2adj
|
R2
|
R2adj
|
R2
|
R2adj
|
R2
|
R2adj
|
R2
|
R2adj
|
R2
|
R2adj
|
R2
|
R2adj
|
R2
|
R2adj
|
Bior1.3
|
91.459
|
88.198
|
91.697
|
88.998
|
89.525
|
86.121
|
88.894
|
85.285
|
89.579
|
85.942
|
88.8799
|
85.2659
|
86.3223
|
81.8771
|
90.0892
|
86.8682
|
Haar
|
91.77
|
88.45
|
91.33
|
88.51
|
88.91
|
85.31
|
89.91
|
86.61
|
89.85
|
86.32
|
88.84
|
85.22
|
86.25
|
81.78
|
90.11
|
86.89
|
Db2
|
90.94
|
87.99
|
90.45
|
87.86
|
88.57
|
84.86
|
89.92
|
86.65
|
85.32
|
81.24
|
86.53
|
82.152
|
82.53*
|
76.85*
|
88.13
|
84.27
|
(*)indicates Insensitive factors |
Table 6
R2 and R2adj values of the most significant proposed features using 5 different mother Wavelets on accumulated detailed signals
R2 & R2adj
|
Haar
|
Db2
|
Db10
|
Sym8
|
Bior1.3
|
R2
|
R2adj
|
R2
|
R2adj
|
R2
|
R2adj
|
R2
|
R2adj
|
R2
|
R2adj
|
max
|
82.27
|
76.51
|
84.45
|
79.4
|
81.09
|
78.9
|
83.61
|
79.25
|
81.58
|
75.6
|
rms
|
75.87
|
68.03
|
78.22
|
71.14
|
81.08
|
74.93
|
80.87
|
74.66
|
75.45
|
67.48
|
std
|
75.87
|
68.03
|
78.22
|
71.14
|
81.08
|
74.93
|
80.87
|
74.66
|
75.45
|
67.48
|
energy
|
66.98
|
56.25
|
69.03
|
58.96
|
70.99
|
61.56
|
70.87
|
61.4
|
66.57
|
55.7
|
entropy
|
76.31
|
68.61
|
78.48
|
71.49
|
81.64
|
75.67
|
81.56
|
75.57
|
77.1
|
69.66
|
Table 6 shows R2 and R2adj values for the accumulated detailed signals. It can be observed that the signal resulting from the sum of the detail signals of all decompositions do not provide significant performance. The accumulated detail signal is not separated into different decompositions and consequently includes additional details from the machining process. As a result, it adversely affects the performance of sensitivity criteria. Figure 8 illustrates the Pareto charts of rms, std, energy, and entropy (features with highest values of R2) obtained from the most appropriate mother wavelets. Based on the presented charts, rms, std, and energy were substantially controlled with the variation of all the proposed cutting parameters, including the cutting speed (A), feed per tooth (B), coating material (D), and depth of cut (C) respectively while for entropy depth of cut (C) can not be assumed a significant parameter. There is a correlation between the levels of proposed cutting parameters, including cutting speed, feed per tooth, coating strength and depth of cut (not being effective on entropy level) and rms, std, energy, and entropy, with Vc as the most effects factor on all the mentioned attributes. The obtained analysis revealed that a considerable proportion of AE signals generated during milling processes are closely linked to levels of consumed energy and material removal rate (MRR), as stated in [43]. Other significant factors on rms and std are the interaction between cutting speeds (AA), coating materials (DD), feed per tooth and depth of cut (BC). The most visible inputs affecting the entropy are cutting speed and feed per tooth (AB). However, in comparison to rms and std, the energy was affected by more statistically significant parameters, including coupled interactions between cutting speeds (AA), coating materials (DD), feed per tooth and depth of cut (BC), cutting speed and feed per tooth (AB), cutting speed and depth of cut (AC), and cutting speed and coating materials (AD).
In the frequency domain, the conclusions revealed that peak amplitude and peak frequency entitled as the most sensitive factors to input catting parameters. They were not still satisfactorily governed by such parameters [44]. The negligible P-Value (<<0.05) of feed per tooth, cutting speed, coating material, and depth of cut when taking rms, std, energy and entropy throughout the wavelet transform analysis of decomposed AE detail signals of milling of Aluminium 7075 was observed and considered. It approves that these cutting parameters remarkably control the variation in maximum amplitude. Cutting speed, depth of cut, coating material details, and feed per tooth shows a strong correlation with AE signals in the time-frequency domain, confirming that AE signals and cutting parameters can be selected appropriately for the purpose of monitoring machining processes. The order of influential cutting parameters on significant attributes of AE signals was shown in Table 7. It is noteworthy that, in general, the milling process signals are more sophisticated than other non-traditional machining methods. As a result, they are significantly affected by system deviations. These signals can include background noise such as mechanical, electrical, or acoustic. Aluminum alloys machining presents challenges such as burr formation, BUE, and adhesion of work parts to the cutting tools [38–41].
The present study certifies the accuracy and effectiveness of AE signal information in milling processes monitoring. According to the obtained information, it can be claimed that AE signals change more by the variation of cutting parameters (cutting speed and feed per tooth) than by changing the coatings. In this study, a second-order model is used to investigate the sensitivity of AE signal parameters, and as the subject of further studies, it is suggested to evaluate more models for statistical analysis on machining data. Furthermore, the method introduced in this study can be utilized with AI-based techniques (e.g., Neural/Deep Network) to develop a robust classification and predictive model and monitor machining operations [45]. Besides, for non-deflecting signals, higher frequency ranges, advanced filtering, and anti-aliasing algorithms are recommended. Finally, it should be noted that the theory of predicting the AE signal parameters is an acceptable approach to avoid the need for repeated tests.
Table 7
Effective cutting attributes on sensitive AE parameters
AE Parameters
|
Cutting speed
|
Feed per tooth
|
Depth of cut
|
Coating material
|
rms
|
1
|
2
|
4
|
3
|
std
|
1
|
2
|
4
|
3
|
energy
|
1
|
2
|
3
|
4
|
entropy
|
1
|
2
|
4*
|
3
|
(*)indicates Non-statically effective factors