Materials Today: Proceedings 80 (2023) 3570–3574

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Materials Today: Proceedings

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Iot monitoring lathe machine performance

Rupak Sharma a, Rajeev Sharma a, Y.B. Prabha b, S. Rema Devi c, Pankaj Saxena d,
T. Rajasanthosh kumar (rajasanthosh) e,⇑
a
Department of Computer Applications, Faculty of Science& Humanities, SRM Institute of Science & Technology, NCR Campus, Delhi NCR Campus, Meerut-Delhi Road,
Modinagar, Ghaziabad, UP, India
b
Department of Computer Science and Engineering, Koneru Lakshmaiah Education Foundation, Vaddeswaram, Guntur, India
c
Department of English, School of Liberal Arts and Special Education Kalasalingam Academy of Research and Education, Krishnankoil, Virudhunagar District, India
d
R.B.S. Management Technical Campus, Agra, India
e
Department of Mechanical Engineering, Oriental Institute of Science & Technology, Bhopal, India

a r t i c l e i n f o a b s t r a c t

Article history: Machines have to operate effectively and free from faults in order to enhance productivity, increase qual-
Available online 27 July 2021 ity, and decrease costs. With automated and flexible action, this is far more likely. An accurate identifi-
cation of the underlying cause Causes of failure that need repairs and the time for restoration include: A
Keywords: lot of Various monitoring methods are available to track the experimentally-recorded machine health.
Lathe machine Maintaining instruments and sensors. The vibration monitoring methods in this list. It is the right fit,
Monetering and it has shown itself over time. Measuring vibrations in this job three different locations resembling
IoT
the stock of a gun: headstock, tailstock. When conducting turning operation with mild steel, the tool post
of the lathe machine is made of metal. Data that is gathered through sensors is sent straight to the cloud
in this case, such as Ubidots IoT platform. via way of nodeMCU. Whether a task is impacted or a tool is
impacted, mission failure has occurred. Thus, in either instance, early warning is provided by a signature,
thus the development does not progress as quickly machining. If the tail-stock seems to be broken, and
this appears to be a consistent problem, then the whole batch must be inspected for errors to be
inspected closely is anything that has been created under such circumstances. An optimal decision-
making procedure light may be thrown on CM so processes may be machine-wise instituted in a shop
there. Tools while talking about lathes that are large, medium, or tiny. Overall it is a method which is easy
but yet capable of benefitting people at all levels, from the absolute beginner to experts Floor productivity
is aided by training elements that are almost unnecessary.
Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Confer-
ence on Nanoelectronics, Nanophotonics, Nanomaterials, Nanobioscience & Nanotechnology.

1. Introduction
Each machine tool wears a portion based on the kind of tool, the
sort of work, and many other considerations. Intermittent wear
and tear makes the tool obsolete at some point. As the tool’s dura-
bility degrades, the accuracy of the task begins to be impaired.
When it is no longer able to generate tasks with particular degree
of acceptable accuracy, it has to be replaced. The standard pro-
cesses are used to keep track of the tool wear and tear. Accelerom-
eters and multichannel high-precision data collection devices are
⇑ Corresponding author at: Oriental Institute of Science & Technology, Bhopal,
India
E-mail address: rajasanthosh@oriental.ac.in (T. Rajasanthosh kumar).
most often used. Lifetime of a tool The amount of time you expect
the tool to be useful is called expectancy. Taylors equation is often
based on cutting speed, depth of cut, feed rate, and material type.
Because of the different manufacturing processes, it is possible that
the anticipated lifespan will vary from the estimated expected life-
time. Some businesses are using standard observations for the tool
and are attempting to get the correct Remaining Useful Life (RUL).
The time that the tool will fail is calculated using RUL (or unusable
in production in simple terminology). RUL prediction is not always
as simple as it seems when described. Researchers are devoting a
significant lot of effort to accurately calculate RUL.
A commonly used method for this is machine learning tech-
niques that include learning techniques. Using machine learning,
the engine analyses and classifies previously supplied data, or uses

https://doi.org/10.1016/j.matpr.2021.07.300
2214-7853/Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Nanoelectronics, Nanophotonics, Nanomaterials,
Nanobioscience & Nanotechnology.
R. Sharma, R. Sharma, Y.B. Prabha et al. Materials Today: Proceedings 80 (2023) 3570–3574

the data to do a prediction analysis on the condition of new data. Table 1

Because of this, methods that use such characteristics are reliant Chemical Composition Of carbide tool bit.

on them. One of the most frequent assessment criteria for gauging Si no Composition Name %
the quality of an instrument is to assess the noise it makes. 1 Wc 81.26
Through the addition of total acceleration in all three directions, 2 Co 16.29
the vibration data is further collected. Time series is also known 3 TiC 1
as a data set that changes with time. The difficulty of RUL in fact
has to do with Time Series Prediction. Other methods used in Neu-
ral Networks include Until Run to Failure (RTF) in a restricted envi- Table 2
ronment, the tool must be utilised, and then the recorded data and Geometry of Carbide tool.
lifespan must be monitored. The traditional approach for efficient
Si.No Description Measured
scheduling and maintenance has been to utilise this method.
Computational and predictive engines have improved, and with 1 Grade Ic 20
2 S in mm 4.77
them the capability to use time series data acquired during RTF in 3 D1 in mm 5.49
RUL computation can be implemented. This means RUL can be 4 R in mm 0.79
interpolated by machine learning algorithms such as Neural Net- 5 1 mm 12.88
works, Support Vector Machines, Curve Fitting, or other
techniques.
3.2. 8-Channel analyzer

2. Specification of components
The machinability investigation of the Al-SiC metal matrix com-
posites will be done using carbide tools. In the current study, the
carbide tool is shown in Fig. 1.
Everything about online condition monitoring which means
\smaintenance is done for equipment from a distance. thus in this
instance vibration signal is sent to\scloud which can be viewed
anywhere using internet and also condition monitoring can be
used for multiple machineries by detecting all machines vibration
at a time and transmitting it to the cloud for analysis at other loca-
tion. See (Fig. 2).
3. Structure of data acquisition system specification of
components
3.1. Data acquisition system
With the implementation of the vibration data collection sys-
tem, tool condition monitoring was made possible via the analysis
of vibration data. See (Table 1 and Table 2).
An 8-channel analyzer allows you to record and examine mea-
surements, such as environment testing, structural analysis, acous-
tics, machinery diagnostics, and production testing and quality
control, using the modular software offered by Data Physics, which
allows you to select only those measurements you need from an
extensive range.
3.3. SignalCalc mobilyzer
All of the components necessary for complete tests of the main
operations are present: strong FFT measurements, large dynamic
range, and comprehensive analysis capabilities. A broad range of
standard features includes selection and conversion of engineering
units, automatic export, professional reports, simple data manage-
ment with signal map, a wide range of displays, and various cursor
functions. Read more about SignalCalc mobilizer on SignalCalc
mobilizer website Application modules with optional features
(real-time Octave and 1/3 Octave analysis, Sound Power and Inten-
sity, RPM-based measures, Order Tracking, MIMO and Stepped Sine
testing, Balancing) are used to increase the usefulness of the anal-
ysis modules and include additional capabilities. Here are seven
SRS analyses, all of which may be broken down into four parts:

Fig. 1. Carbide Tool.

Fig. 2. Proposed methodology block diagram.

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R. Sharma, R. Sharma, Y.B. Prabha et al.
Fig. 3. Experimental Setup.
Fig. 4. Accelerometer mounted on the tool holder.
Demodulation, rotor dynamics, multi-plane balancing, waterfall
and spectrogram presentations, and throughput-to-disk.
3.4. 8-Channel data recorder
Set-up time is a concern when using TEAC data recorders (es8
recorders) in the field or in the laboratory. This figure displays
the ES8 recorder in Fig. 3 7. For recording, the es8 recorder utilises
a Compact Flash memory card. An individual stand-alone opera-
tion enables you to configure, monitor, and record using the LCD
and the key. You may conduct the wave monitor and the recording
control by connecting to a PC with a built-in USB port. While the
device is sampling on all channels, four hours of continuous
recording may be done utilising the device’s 16-bit A/D converter
that is separately fitted in each channel. An extra battery will allow
you to record longer. A sample frequency of 5 kHz to 1/60 Hz is
provided. The different kinds of sensor amplifiers combined with
combine measurement (such earthquakes, natural phenomena,
and structure vibrations) makes it feasible to measure a broad vari-
ety of parameters (such as structural vibration, mechanical vibra-
tion, and bio-signals). The analyzer’s sensor serves as a backup
for the device. They are designed to be cheap and easy to use
front-end components.
3.5. Kistler amplifier
To examine and calibrate piezoelectric measuring systems, you
may use the charge calibrator. In the place of the sensor or in tan-
dem with it, the charge calibrator is linked to the measurement
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Materials Today: Proceedings 80 (2023) 3570–3574
chain. The number of charge amplifiers that may be linked is lim-
ited to five. [Kistler] To launch the operation, please use the key-
board or an alternative interface. The LCD shows the settings.
One example of an application would be a charge calibrator which
is connected to between one and five charge amplifiers.
3.6. Kistler tri axial accelerometer
For machine monitoring purposes, it is essential to have vibra-
tion sensors in place. Triaxial accelerometers of the type
8766A250AA and 8766A5BB are designed for use in harsh environ-
ments. This shear element design, called Kistler’s PiezoStar, is used
for its large working frequency range and resistance to tempera-
ture fluctuations. Other sensing element designs use PiezoStar
crystals and integrated hybrid microelectronics to decrease sensi-
tivity fluctuation with respect to operation temperature.
4. Experimental setup and test procedure
The use of tri axial accelerometers in previous TCM research has
been confirmed in a TCM review. Fig. 3 shows completed installa-
tions of a data collection system using a standard lathe.The Kistler
amplifier is adjusted to 105.3 Hz in terms of requirements. In Fig. 4,
the accelerometer was placed on the tool shank that holds the cut-
ting tool. The accelerometer was used to find signals which were
then amplified and recorded. Data acquisition software saved the
signals (data physics), variable tool-wear carbide insert tools (nor-
mal carbide tool, medium worn-out tool, fully worn-out tool)
Approximately equal quantities of LM6 (LM6 + 0.2 percent SiC;
LM6 + 4.3 percent SiC; LM6 + 11 percent SiC) were placed in stan-
dard lathes to cut LM6 work pieces, changing in composition with
variable speed, feed, and depth of cut
The accelerometer was attached to the tool holder to capture
the vibration data produced in the machining operation. See
Fig. 5 for further information. An 8-channel analyzer was used to
capture vibration signals that were produced and amplified by
the kistler amplifier. The channels for measuring the amount of
force data were captured and programmed.
An understanding of the industrial architecture of the process,
components and their arrangements for machine tool health mon-
itoring. The arrangement is basically collecting accelerometer data
at a very high sampling rate (think audio recording-22 kHz) and
then storing it. If an online analysis of this data has to be carried
out, the data needs to be placed in cloud at a very rapid pace with-
out loosing connection or losing out the values. With 16 bit ADC
recording 3 channels @ 22Khz leads to 48x22000 = 1.5 KB data
per second. A 20 h of recording will result in approximately
R. Sharma, R. Sharma, Y.B. Prabha et al. Materials Today: Proceedings 80 (2023) 3570–3574

Fig. 5. Operation on lathe machine.

Fig. 6. Tail stock frequency Vs Amplitude.

Fig. 8b. Tool post frequency Vs Amplitude.

Fig. 9. Tail stock amplitude Vs time.

Fig. 7. Head stock amplitude Vs time.

Fig. 10. Tail stock frequency Vs amplitude.

Fig. 8a. Tool post Amplitude vs time.

950 MB data. That’s very large for processing in the memory.
Therefore many times this data is re sampled at 500 HZ-1Khz to
decrease amount of samples. We have given some example record-
ing with this post which may be useful for you to evaluate the type
and complexity of data.
These three columns provide information about , y, and z axis
acceleration. Because there is a huge amount of data, we need a
specialised method of data storage called data streaming.
1. record the data locally
2. open a connection with the server
3. send a set of data at a stretch with a timestamp identification

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Table 3
Experimental values.
No. Of Samples Tool Spindle speed in rpm
A A 250
B
C
B A 550
B
C
C A 800
B
C
4. Server must store the data in chunks and must offer the analytic
service this acceess of data in chunk
While current cloud-based IoT service providers often suffer
from one major flaw, they presume that each data point is an inde-
pendent time stamp. Data is thus seen as a single instance of time’s
worth of data. Where did it all go wrong? Azure, Bluemix, and
allied IoT cloud storage/service providers use either Mqtt or Web-
sockets for their IoT cloud storage/service. The serial transmission
of data occurs as a sequence but with time-stamping on top of it.
As a result, GE Predix is the top competitor in this category. Data
is delivered in chunks with a unique ID and a time series linked
with the individual values or overall chunk. This design divides
up functionality into separate services, each of which may be cre-
ated and deployed independently. Additionally, Amazon Web Ser-
vices (AWS) is used, which helps with scalability. As you climb, you
may pay as you go. Our cloud-based User and Application Authen-
tication Architecture, UAA, secures data access and sharing from
the beginning. This GE predix also offers a visualisation solution
for both logical and presentation layers, utilising the Custom View
service (using Angular JS based Px components).
With all the tools required to complete the end-to-end data col-
lection and visualisation service, you receive a full outfit. However,
it is worth mentioning that even though the platform is capable of
managing and structuring large amounts of industrial and machine
data, it lacks the power of powerful machine learning techniques.
As a result, IBM Bluemix and Microsoft Azure clearly have an
advantage when it comes to analysing the data. Using Predix to
gather your data and Watson or Azure to analyse it is an excellent
approach to create your RUL framework. The next step is to make
the architecture available as a service via the cloud, and have the
apps use it. Here, we will investigate how to create a Microservice
using GE Predix to access sensor data. The simulation framework,
powered by the Intel Edison board, will enable us to do a basic
hands-on analysis of the data collecting process, demonstrate ser-
vice scalability, robustness, and finally proceed with the real-time
integration process.
5. Results and discussions
5.1. Without performing turning operation
See (Fig. 6, Fig. 7, Fig. 8a, Fig. 8b, Fig. 9, and Fig. 10).
6. Conclusion
We’ve covered how to measure tool lifetimes in real-world
industrial settings using accelerometer data in this paper. In addi-
tion to this, we have included the sensors and other components
with the industrial installation and industry-accepted standards
for data collection. Then we have developed Predix time series
based data streaming and ingestion services for moving the data
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Materials Today: Proceedings 80 (2023) 3570–3574
Depth of cut in mm Vibration in Hz
2 25,600
2 25,600
2 25,600
collecting process to cloud. Then, we simulated the industrial set-
ting and tested the service using Intel Edison, all using a simulation
technique.
We’ve also made available the dataset as recorded, the 003th
row in Table 3 is the first, the 4th row is the second, and so on.
You may manually upload the RTF data to Azure and then con-
struct your RUL system using machine learning services like Azure.
Enthusiasm, this guide should help you get started with IIoT and
make it simple for you to quickly form your IIoT architecture.
CRediT authorship contribution statement
Rupak Sharma: Conceptualization, Methodology, Data cura-
tion. Rajeev Sharma: Visualization. Y.B. Prabha: Investigation. S.
Rema Devi: Writing - original draft. Pankaj Saxena: Validation.
T. Rajasanthosh kumar: Supervision.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
Further Reading
[1] L. Ren, L. Zhang, F. Tao, C. Zhao, X. Chai, X. Zhao, Cloud manufacturing: from
concept to practice, Enterp. Inf. Syst. 9 (2) (2015) 186–209.
[2] B. Buckholtz, I. Ragai, L.H. Wang, Cloud manufacturing: current trends and
future implementations, Journal of Manufacturing Science and Engineering,
137, 4, 2015, p. 040902-1-9.
[3] X. Xu, From cloud computing to cloud manufacturing, Rob. Comput. Integr.
Manuf. 28 (1) (2012) 75–86.
[4] R.Y. Zhong, Q.Y. Dai, T. Qu, G.J. Hu, G.Q. Huang, RFID-enabled real-time
manufacturing execution system for mass-customization production.
[5] C. Wei, Y. Lee, K. Cao, et al., Implementation of a data acquisition system for
heterogeneous machines[C]//2017 IEEE/SICE International Symposium on
System Integration (SII). IEEE, 2017: 232-235.
[6] S. Singh, R. Garg, P.K. Mishra, Performance optimization of map reduce-based
apriori algorithm on hadoop cluster, Comput. Electr. Eng. 67 (2018) 348–364.
[7] S. Nithya, L. Shree, Kiruthika, Krishnaveni, Solar based smart garbage
monitoring system using IOT, International Journal of Electronics and
Communication Engineering and Technology, 8(2), 2017, pp. 75–80.
[8] H.C. Punjabi, S. Agarwal, V. Khithani, V. Muddaliar, M. Vasmatkar, Smart
farming using IoT, International Journal of Electronics and Communication
Engineering and Technology, 8(1), 2017, pp. 58–66.
[9] V. Uma Maheswari, S. Shoba Rani, D. Divakara Reddy, B. Lakshmi, E-Bazaar
innovation using IoT device in cloud subscription management, Int. J. Civil Eng.
Technol. 8 (8) (2017) 1155–1158.
[10] S. Manikyam, S. Sampath Kumar, K.V. Sai Pavan, T.R. Kumar, Laser heat
treatment was performed to improve the bending property of laser welded
joints o low-alloy ultrahigh-strength steel with minimized strength loss, 83,
2019, 2659-2673.
[11] S. Siddam, S. Todupunuri, P. Reddy, T. Kumar, Duplex stainless steel welding
microstructures have been engineered for thermal welding cycles & nitrogen
(N) gas protection Materials Today: Proceedings. 2021, 10.1016/
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[12] K.B. Sai Sanjana, K. Sai Mounika, T. Raja Santhosh Kumar, D.V. Srikanth,
Thermal analysis of advanced IC engine cylinder, International Journal of
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