Condition-Aware Autoencoder and Transfer Learning-Based Estimation of Milling Cutting Forces from Spindle Vibration Signals

Cutting force is a critical indicator reflecting the interaction between the cutting tool and the workpiece in machining processes. Conventional measurement methods using dynamometers are accurate but costly and challenging for real-time applications. This study proposes a novel transfer learning-based method for estimating milling cutting forces using only spindle vibration signals without direct force sensors. The proposed approach consists of two stages: First, an autoencoder is trained with measured cutting force data to construct a latent feature space. Second, a target encoder aligns spindle vibration signals to this latent space, allowing the decoder to reconstruct estimated cutting forces. To reflect machining parameters into the learning model, the input dataset was constructed by integrating material type, cutting speed, and cutting direction as additional inputs into each model’s inputs. Experiments were conducted on Ti-6Al-4V and STS316L workpieces under various machining conditions. Under normal conditions, the proposed method achieved an average Pearson correlation coefficient (PCC) of 0.9213 (Fx) and 0.9072 (Fy). Under abnormal transient conditions, robust performance was maintained, with PCC values of 0.8573 (Fx) and 0.9202 (Fy). The results demonstrate that the proposed method can effectively monitor cutting forces and reflect changes across a variety of machining environments using only vibration signals.