Vibration based tool wear monitoring in end milling of S50C via a low-cost data acquisition system

Amir Shariffuddin, Nur Adha Raihana and Mokhtar, Suhaily and M.A.M., Adib Arham and M.A.M., Iman Zul Hakim and Md Nor, Khairul Affendy and Antong, Hasmawati (2026) Vibration based tool wear monitoring in end milling of S50C via a low-cost data acquisition system. Journal of Mechanical Engineering and Technology, 18 (1). pp. 45-53. ISSN 2180-1053 E-ISSN 2289-8123

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Abstract

Milling operations are essential in modern manufacturing due to their ability to produce complex and high-precision components. However, excessive heat generation and vibration during cutting can accelerate tool wear, resulting in reduced tool life, compromised product quality, and unexpected machine downtime. This study presents the development of a real-time tool condition monitoring system using an Arduino-compatible microcontroller platform. The system integrates a microcontroller with an infrared temperature sensor, a tri-axis accelerometer, and cloud technology to capture and analyse vibration and temperature data during machining. Experimental trials were conducted on S50C carbon steel using carbide cobalt end milling tools at various spindle speeds. Predefined vibration and temperature thresholds were set as indicators for maintenance alerts, at which vibration levels above 6 m/s2 and temperatures exceeding 70°C triggered warning signals via LEDs and buzzers. The results show rising vibration and temperature readings corresponding to progressive tool wear, confirming their effectiveness as condition monitoring indicators. The system enables immediate on-site alerts through visual and audible signals, as well as remote monitoring via a cloud dashboard, providing a practical and low-cost solution for enhancing operational reliability in smart manufacturing environments

Item Type:	Article (Journal)
Uncontrolled Keywords:	Tool Wear, Vibration Signals, IoT, Data Acquisition
Subjects:	T Technology > TJ Mechanical engineering and machinery T Technology > TJ Mechanical engineering and machinery > TJ212 Control engineering
Kulliyyahs/Centres/Divisions/Institutes (Can select more than one option. Press CONTROL button):	Kulliyyah of Engineering > Department of Manufacturing and Materials Engineering Kulliyyah of Engineering > Department of Mechatronics Engineering
Depositing User:	Dr. Suhaily Mokhtar
Date Deposited:	24 Aug 2026 09:55
Last Update:	24 Aug 2026 09:55
Queue Number:	2026-08-Q4884
URI:	http://irep.iium.edu.my/id/eprint/130976

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