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On the potential of low-cost instrumentation for digitalization of legacy machine tools

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Abstract

Smart manufacturing is the convergence of Industry 4.0 technologies that modernize production systems, with a growing demand for real-time active management to maximize processes. Companies with outdated, non-communicative or non-data-transmitting machine tools urgently need new technologies to ensure competitiveness. A viable option is smart retrofitting, which involves upgrading legacy equipment to bring them into the digital age. This article presents a study on the potential of digitizing legacy machine tools to improve productivity and surface quality through low-cost instrumentation. Low-cost sensors and hardware were installed on a universal lathe for continuous and real-time monitoring of the turning process. The results confirmed the influence of cutting speed and feed rate on surface finish, while the instrumentation showed good results in monitoring rotation and feed rate. The results of this paper contributes to recent research in process monitoring and enables a solid analysis of the benefits of real-time monitoring of machining in universal mechanical lathes.

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Acknowledgements

The 1st author would like to thank SENAI Oscar Lúcio Baldan school for the technical support. The 3rd author would like to thank the National Council for Scientific and Technological Development (CNPq) for his technological productivity fellowship (process 302814/2021-3) and, also, FAPESP for Grant 2019/22115-0.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Universidade Federal de São Carlos, Rodovia Washington Luís, km 235, São Carlos, 13565-905, São Paulo, Brazil

    Paulo de Tarso Durigan, Sidney Bruce Shiki, Gustavo Franco Barbosa & Armando Ítalo Sette Antonialli

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  1. Paulo de Tarso Durigan
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  2. Sidney Bruce Shiki
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  3. Gustavo Franco Barbosa
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  4. Armando Ítalo Sette Antonialli
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Contributions

All author(s) contributed to the construction of the paper as follows:

– Paulo de Tarso Durigan: instrumentation design, machining tests, statistical analysis, and writing.

– Sidney Bruce Shiki: instrumentation design, signal processing, statistical analysis, and writing.

– Gustavo Franco Barbosa: experimental design, machining tests, and writing.

– Armando Ítalo Sette Antonialli: machining tests and material characterization.

Corresponding author

Correspondence to Sidney Bruce Shiki.

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Durigan, P.d.T., Shiki, S.B., Barbosa, G.F. et al. On the potential of low-cost instrumentation for digitalization of legacy machine tools. Int J Adv Manuf Technol 128, 1929–1941 (2023). https://doi.org/10.1007/s00170-023-11946-5

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