Leveraging IoT in Auto Component Manufacturing to Monitor Surface Roughness and Tool Temperature

Surface finish is an important requirement in Auto Component Manufacturing that defines the quality of work piece obtained from turning operations. Thus to reduce downtime due to rejection of work piece for its surface finish a continuous monitoring of surface roughness based on its cutting parameter and vibration signal is required. Similarly it is also important to monitor the cutting tool temperature to have a longer tool life. With the emerging trend of Internet-of-Things (IoT) it has become very easy to collect the required data, storing it, analysing it and also alerting the required personnel through the mobile application, e-mail and SMS. The stored data and analysis could reveals in depth the process, which leaves a large scope for improvement of the system. The paper discusses the implementation of IoT to collect data of vibration signal and cutting tool temperature of dry turning operation, for cutting parameter like 1) spindle speed 2) feed rate and 3) depth of cut for three different material mild steel (MS), brass and aluminium (Al). A correlation was obtained to predict surface roughness and tool temperature. The system developed could give a real time monitoring of surface roughness on a smart phone that can be used as a tool for optimizing the turning process to give improved quality and increased production volume.