Machine-Learning- and Internet-of-Things-Driven Techniques for Monitoring Tool Wear in Machining Process: A Comprehensive Review

Sudhan Kasiviswanathan, Sakthivel Gnanasekaran, Mohanraj Thangamuthu, Jegadeeshwaran Rakkiyannan

Tool condition monitoring (TCM) systems have evolved into an essential requirement for contemporary manufacturing sectors of Industry 4.0. These systems employ sensors and diverse monitoring techniques to swiftly identify and diagnose tool wear, defects, and malfunctions of computer numerical control (CNC) machines. Their pivotal role lies in augmenting tool lifespan, minimizing machine downtime, and elevating productivity, thereby contributing to industry growth. However, the efficacy of CNC machine TCM hinges upon multiple factors, encompassing system type, data precision, reliability, and adeptness in data analysis. Globally, extensive research is underway to enhance real-time TCM system efficiency. This review focuses on the significance and attributes of proficient real-time TCM systems of CNC turning centers. It underscores TCM’s paramount role in manufacturing and outlines the challenges linked to TCM data processing and analysis. Moreover, the review elucidates various TCM system variants, including cutting force, acoustic emission, vibration, and temperature monitoring systems. Furthermore, the integration of industrial Internet of things (IIoT) and machine learning (ML) into CNC machine TCM systems are also explored. This article concludes by underscoring the ongoing necessity for research and development in TCM technology to empower modern intelligent industries to operate at peak efficiency.