In-situ characterization of tool temperatures using in-tool integrated thermoresistive thin-film sensors

Metal cutting is characterized by high temperatures at the tool-workpiece interface. Although valuable information could be provided by the temperature values, their direct measurement still presents a challenge due to the high contact pressure and the inaccessibility of the process kinematic. In th...

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Bibliographic Details
Published inProduction engineering (Berlin, Germany) Vol. 17; no. 2; pp. 319 - 328
Main Authors González, Germán, Plogmeyer, Marcel, Schoop, Julius, Bräuer, Günter, Schulze, Volker
Format Journal Article
LanguageEnglish
Published Berlin/Heidelberg Springer Berlin Heidelberg 01.04.2023
Springer Nature B.V
Subjects
Contact pressure
Cutting tools
Engineering
High temperature
Industrial and Production Engineering
Kinematics
Metal cutting
Production
Quality
Sensors
Temperature
Temperature distribution
Thin films
Workpieces
Temperature measurement
Thin-film sensor
Orthogonal cutting
High-speed imaging
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Summary:Metal cutting is characterized by high temperatures at the tool-workpiece interface. Although valuable information could be provided by the temperature values, their direct measurement still presents a challenge due to the high contact pressure and the inaccessibility of the process kinematic. In this research work, the current state of thin-film sensors for measuring temperatures on the chip-tool interface has been analyzed with a focus on the measuring phenomena: thermoelectricity and thermoresistivity. Thin-film sensors placed on the cutting tools in or close to the tool-chip contact area are expected to obtain accurate temperature information at the expense of a short lifetime. New insights into thin-film sensors manufacturing, design and calibration are presented, and a new concept of a three-point thermoresistive thin-film sensor is proposed. During orthogonal cutting tests the workpiece deformations were measured through high-speed imaging and the process temperatures were measured with thin-film sensors. In order to validate the temperatures and to obtain the temperature distribution on the cutting edge, Finite Element simulations were carried out. Finally, the potential of using cutting tools with integrated thin-film sensors for in-situ characterization is investigated and a statement for its limitations and potential applications is given.
ISSN:0944-6524
1863-7353
DOI:10.1007/s11740-023-01186-7