Development of smart machining 2

Humans are constantly innovating and striving to improve the quality of life. Over the years, new technologies have been developed and incorporated into existing industrial processes. These breakthroughs and significant improvements in productivity have led to three industrial revolutions and currently, the world has advanced to the fourth stage of industrial production. Despite most industries are aware of Industry 4.0 by now, not many are successful in implementing this concept or willing to adopt this new strategy. It proves to be a long and arduous transformation, and different industries require different system configurations. The objective of this research is to learn the ways of developing a smart machining system and implementing the concept of a cyber-physical system (CPS). Through this research, the author aims to develop a more robust smart system and gain experience in providing effective methods to aid the industries in implementing Industry 4.0. A machining system is rendered ‘smart’ through the application of a cyber-physical system whereby physical processes can be monitored and controlled with a feedback loop. In this report, Turning is the machining process discussed. To develop a smart machining system, creating a CPS is the first major step. Smart sensors and devices, that are attached to a CNC Turning machine, will be integrated with a data acquisition platform and a system engineering software. As part of the implementation, tests were carried out with the integrated system to determine the effects of tool wear and that prediction of tool wear is possible. Results were shown that tool wear has a negative impact on surface roughness, cutting force, and power consumption. These resulted in poorer product quality and higher machining costs. The application of coolant is also observed to improve product surface finishing and ease tool wear. In this research, the smart machining system is not fully developed but the CPS is established and implemented. Future work is suggested to further develop the smart machining system.Bachelor of Engineering (Mechanical Engineering