In the heart of Vienna, researchers at the Institute of Production Engineering and Photonic Technologies at Technische Universität Wien (TU Vienna) are pioneering a breakthrough that could redefine the future of manufacturing, particularly in the energy sector. Friedrich Bleicher, the lead author of a recent study published in *Metrology* (translated to English as “Measurement Science”), has been exploring how real-time surface roughness measurements can revolutionize tool wear monitoring and predictive maintenance in machining processes.
The study, titled “Study on the Correlation Between Surface Roughness and Tool Wear Using Automated In-Process Roughness Measurement in Milling,” delves into the growing trend of integrating measurement systems directly into production processes. This shift from traditional measurement laboratories to in situ metrology is a game-changer, offering immediate data that can drive smarter, more efficient manufacturing decisions.
Bleicher and his team have developed a roughness measurement device that can be seamlessly integrated into machine tools. This innovation is not just about assessing surface roughness; it’s about leveraging this data to monitor tool wear and adjust cutting parameters in real-time. “By linking surface measurements with tool wear monitoring, we can establish a correlation between surface roughness and wear progression of indexable inserts in milling,” Bleicher explains. “This represents a first step toward integrating in situ metrology into closed-loop control in machining.”
The experimental setup followed ISO 8688-1 guidelines for tool life testing. Indexable inserts were operated throughout their entire service life while surface roughness was continuously recorded. In parallel, cutting edge conditions were documented using focus variation microscopy. The results revealed a consistent three-phase pattern: initially stable roughness, followed by a steady increase due to flank wear, and an abrupt decrease in roughness linked to edge chipping.
These findings have significant implications for the energy sector, where precision and efficiency are paramount. In industries such as oil and gas, wind energy, and renewable energy, the ability to monitor tool wear in real-time can lead to substantial cost savings and improved operational efficiency. Predictive maintenance, enabled by this technology, can prevent unexpected downtimes and extend the life of critical tools.
Bleicher’s research is a testament to the power of data-driven manufacturing. By integrating roughness measurement devices into machine tools, manufacturers can achieve a higher level of control and precision. This not only enhances the quality of the final product but also optimizes the entire production process.
As the energy sector continues to evolve, the demand for smart and data-driven manufacturing technologies will only grow. Bleicher’s work at TU Vienna is at the forefront of this revolution, paving the way for a future where in situ metrology is a standard practice in machining processes. The study, published in *Metrology*, is a significant step forward in this journey, offering a glimpse into the potential of real-time monitoring and predictive maintenance in the energy sector and beyond.