Summary

This project presents a Simulink-based architecture model for predictive tool wear monitoring using vibration analysis and FEA-based simulation. The system comprises five key functional blocks: Tool Wear Setup, Sensor Module, Microcontroller, FEA + Vibration Analysis Engine, and a Predictive Model with GUI and logging. It simulates machining conditions, generates vibration signals, performs structural analysis, and evaluates tool condition based on stress, mode shape, and severity metrics. Interconnected through bus signals, the system enables real-time monitoring and alerts, aiding in predictive maintenance. MATLAB Simulink, along with toolboxes like Signal Processing and Simscape, is used to implement, simulate, and visualize the complete workflow.