Investigation on a Real Time Monitoring System with a Non-contact Device to Minimize Surface Roughness on Metal pieces

Physical contact between stylus and worksurface tends to wear out easily on the stylus profilometers generating more surface roughness. This paper aimed to eliminate these limitations by leveraging optical measurement techniques. At the outset, the research posed several challenges, particularly in adapting optical measurement principles to an industrial machining environment. However, by following a structured approach, this was able to navigate these complexities effectively. The process involved an in-depth study of laser reflection techniques, testing red laser diodes with light sensors such as the BH1750 and photodiodes, and determining the optimal mounting angles and distances to ensure precise roughness measurements. Additionally, the focus was on data analysis and calibration to improve measurement accuracy. Regular discussions with Computer Numerical Control operators and quality control engineers further helped refine the system for practical application. Major Findings: Surface roughness profilometer when used over the workpieces of metals gives a reading on the stylus which is not approximate than non-contact surface roughness measurement devices. The experiment conducted between both contact and non-contact devices shows a most important parameter of measurement which is surface roughness that gives accurate reading on the metal pieces with non-contact measurement device.