This article presents a cloud-based system for the on-line monitoring of tool conditions in end milling. The novelty of this research is the developed system that connects the IoT (Internet of Things) platform for the monitoring of tool conditions in the cloud to the machine tool and optical system for the detection of cutting chip size. The optical system takes care of the acquisition and transfer of signals regarding chip size to the IoT application, where they are used as an indicator for the determination of tool conditions. In addition, the novelty of the presented approach is in the artificial intelligence integrated into the platform, which monitors a tool’s condition through identification of the current cutting force trend and protects the tool against excessive loading by correcting process parameters. The practical significance of the research is that it is a new system for fast tool condition monitoring, which ensures savings, reduces investment costs due to the use of a more cost-effective sensor, improves machining efficiency and allows remote process monitoring on mobile devices. A machining test was performed to verify the feasibility of the monitoring system. The results show that the developed system with an ANN (artificial neural network) for the recognition of cutting force patterns successfully detects tool damage and stops the process within 35 ms. This article reports a classification accuracy of 85.3% using an ANN with no error in the identification of tool breakage, which verifies the effectiveness and practicality of the approach.

The machinability of steel is a crucial factor in manufacturing, influencing tool life, cutting forces, surface finish, and production costs. Traditional machinability assessments are labor-intensive and costly. This study presents a novel methodology to rapidly determine steel machinability using spark testing and convolutional neural networks (CNNs). We evaluated 45 steel samples, including various low-alloy and high-alloy steels, with most samples being calcium steels known for their superior machinability. Grinding experiments were conducted using a CNC machine with a ceramic grinding wheel under controlled conditions to ensure a constant cutting force. Spark images captured during grinding were analyzed using CNN models with the ResNet18 architecture to predict V15 values, which were measured using the standard ISO 3685 test. Our results demonstrate that the created prediction models achieved a mean absolute percentage error (MAPE) of 12.88%. While some samples exhibited high MAPE values, the method overall provided accurate machinability predictions. Compared to the standard ISO test, which takes several hours to complete, our method is significantly faster, taking only a few minutes. This study highlights the potential for a cost-effective and time-efficient alternative testing method, thereby supporting improved manufacturing processes.

In today's rapidly evolving business landscape, the strategic adoption of virtual manufacturing methods has emerged as a key driver for companies seeking to streamline operations and expedite product launches in a cost-effective manner. This progressive approach involves the creation of a synthetic and interconnected environment, empowered by advanced software tools and systems, including Virtual Reality and Simulation technologies, tailored to optimize industrial processes. Our methodology employs a unique combination of two simulation software tools: Factory I/O for process development and MATLAB for control program implementation. Furthermore, we explore the use of the Modbus TCP/IP communication protocol as the framework for seamless interaction between these software tools during simulation. This research presents practical insights into the transformative potential of virtual manufacturing, showcasing its real-world application in enhancing operational efficiency and agility within industrial settings.

Accurate and efficient evaluation of steel properties is crucial for modern manufacturing. This study presents a novel approach that combines spark imaging and deep learning to predict carbon content in steel. By capturing and analyzing sparks generated during grinding, the method offers a fast and cost-effective alternative to conventional testing. Using convolutional neural networks (CNNs), the proposed models demonstrate high reliability and adaptability across different steel types. Among the tested architectures, MobileNet-v2 achieved the best performance, balancing accuracy and computational efficiency. The findings highlight the potential of machine vision and artificial intelligence in non-destructive steel analysis, providing rapid and precise insights for industrial applications.