DEPARTMENT OF MECHANICAL ENGINEERING

IOT - Based Data Capturing System in Machining

Roston Mascarenhas (4NM18ME125) Rolan Gomes (4NM18ME121)

V Sudeesh Kamath (4NM18ME166) Vivan Jude Lobo (4NM18ME175)

Guide: Dr. Grynal D’Mello, Assistant Professor Gd-III, Dept. of Mechanical Engineering

Traditional machining consists of turning, milling, grinding and drilling. which

are some of the most common operations in the manufacturing industry. While the
workpiece is machined, the contact between the cutting tool and workpiece causes
the shape of the tool to deform, either gradually through tool wear, or suddenly
through breakage. This leads to the undesirable effect of downtime in the industry.
Some sources that lead to downtime are unavoidable and necessary, such as the
maintenance of machinery. However, other sources of downtime can be avoided, for
example, the downtime caused by the tool wear or tool breakage. Worn out tools
also result in extra strain on the processing equipment and reduced quality loss of
the machined workpiece, in addition to the increased power consumption.

This project aims to address these issues through the design and
development of a device that combines the processes of tool condition monitoring,
vibration capturing and surface roughness detection, for use on a CNC machine.
The device is to be housed as a compact entity with networking capabilities for the
sharing of data. Therefore, various detection methods are to be scrutinized in terms
of compactness, simplicity and accuracy with the resulting selection being
implemented by optimizing the cost.

A system architecture is to be developed for an IoT-enabled manufacturing

system and adapted for use on a CNC machine. Sensors available in the market are
to be evaluated based on their cost, accuracy and compactness. The designed
system is to take manufacturing inputs as G-Codes (from the user via the internet)
and stream the output of data from all the sensors along with the aforementioned
data to the internet. Engineering implementation of the system as well as its
underlying ideology will also be discussed. Micro-Electromechanical System (MEMS)
sensors will be considered initially as they are economical, compact and tend to work
with a variety of IoT enabled systems. This work evaluates the feasibility of using
them, along with other options, for simultaneous condition monitoring in machining.

The possible outcomes of the project may be summarized as follows:

 Explore and evaluate the different methodologies available and formulate

novel methods if necessary.
 Evaluate the financial aspect of the project and its benefits to the consumer.
 Monitor the tool wear, vibration and surface roughness in real-time.
 Integrate the system as a primary unit in the manufacturing industry under the
“Industry 4.0” concept.
 Utilize the data obtained for further processing or prevention of tool failure.