Application of sophisticated sensors to advance the monitoring of machining processes: analysis and holistic review

Response measurement of various functionality states of machines is an inevitable part of smooth production. An effectively efficient measurement and control system of the machinery helps the inspection engineers to detect failures. In the recent age, the concept of industry 5.0, which focuses on the interaction between humans and machines, has increased the importance of sensors in the industry. Various sensing devices may aid and support the machining process, making it more efficient. These sensing devices support machine tools and enhance productivity by reducing failures. The application of an online monitoring system that includes vibration measurement and tool wear measurement, and the electrical energy consumption is getting fame in industry and academia. This paper mainly presents a holistic review of various sensors and their application in the manufacturing processes. Advancements in the sensor for quality measurement, cutting force measurement, and tool wear measurement are discussed. Furthermore, the adoption of the Internet of Things (IoT) in machining processes and conversion of conventional manufacturing processes into modern digitalized systems are discussed. Recent trends of research to improve the sensor technology have been improved. This study provides fundamental guidelines for using and adopting the various types of sensors in machining processes.