Diffusion Based Data Synthesis for Enhanced Tool Wear Segmentation

Procedia CIRP, vol. 146, pp. 505–510

Abstract

Accurate tool wear segmentation is essential for automated machining. However, deep learning models often require large labeled datasets that are rarely available in industrial environments. Limited image quality, diverse tool geometries, and costly annotation constrain data volume and weaken model robustness. This study proposes a diffusion based data synthesis framework to enhance wear segmentation under small sample conditions. A DreamBooth fine-tuned Stable Diffusion Inpainting model generates realistic wear patterns while preserving tool geometry, guided by structured prompts and a patch conditioned masking strategy. The synthetic data are used to retrain a U-Net segmentation network, achieving about 6% improvement in Dice coefficient on unseen tool types. Results demonstrate that combining real and diffusion-generated data effectively mitigates data scarcity and improves generalization, offering a practical approach for reliable tool wear monitoring in industrial applications.

Authors 4

1. Zongshuo Li corresponding Aachen Manufacturing Technology Institute (MTI)

   RWTH Aachen University

   Affiliation as printed

   Manufacturing Technology Institute (MTI) of RWTH Aachen University, Campus-Boulevard 30, 52074 Aachen, Germany

2. Ding Huo Aachen Manufacturing Technology Institute (MTI)

   RWTH Aachen University

   Affiliation as printed

   Manufacturing Technology Institute (MTI) of RWTH Aachen University, Campus-Boulevard 30, 52074 Aachen, Germany

3. Markus Meurer Aachen Manufacturing Technology Institute (MTI)

   RWTH Aachen University

   Affiliation as printed

   Manufacturing Technology Institute (MTI) of RWTH Aachen University, Campus-Boulevard 30, 52074 Aachen, Germany

4. Thomas Bergs Aachen Fraunhofer Institute for Production Technology IPT Manufacturing Technology Institute (MTI)

   RWTH Aachen University · Fraunhofer Institute for Production Technology IPT

   Affiliation as printed

   Fraunhofer Institute for Production Technology IPT, Steinbachstr. 17, 52074 Aachen, Germany

   Manufacturing Technology Institute (MTI) of RWTH Aachen University, Campus-Boulevard 30, 52074 Aachen, Germany