Process Monitoring of One-Shot Drilling of Al/CFRP Aeronautical Stacks Using the 1DCAE-GMM Framework

This study explores advanced process monitoring for one-shot drilling of aeronautical stacks made of aluminium 2024 and carbon fibre-reinforced polymer (CFRP) laminates using a 4.8 mm diameter drilling tool and unsupervised machine learning techniques. An experimental campaign is conducted to collect thrust force and torque signals at a 10 kHz sampling rate during the drilling process. These signals are employed for real-time process monitoring, focusing on material change detection and anomaly identification, where anomalies are defined as holes that fail to meet predefined quality criteria. An innovative approach based on unsupervised learning is proposed to enable automatic material change identification, signal segmentation, feature extraction, and hole quality assessment. Specifically, a semi-supervised approach based on a Gaussian Mixture Model (GMM) and 1D Convolutional AutoEncoder (1D-CAE) is employed to detect deviations from normal drilling conditions. The proposed method is benchmarked against state-of-the-art supervised techniques, including logistic regression (LR) and Support Vector Machines (SVMs). Results show that these traditional models struggle with class imbalance, leading to overfitting and limited generalisation, as reflected by the F1 scores of 0.78 and 0.75 for LR and SVM, respectively. In contrast, the proposed semi-supervised approach improves anomaly detection, achieving an F1 score of 0.87 by more effectively identifying poor-quality holes. This study demonstrates the potential of deep learning-based semi-supervised methods for intelligent process monitoring, enabling adaptive control in the drilling process of hybrid stacks and detecting anomalous holes. While the proposed approach effectively handles small and imbalanced datasets, further research into the application of generative AI could enhance performance, aiming for F1 scores above 0.90, thereby supporting adaptation in real industrial environments with high performance.