Wear-resistive thin-film sensors on cutting tools for in-process temperature measurement

In-process control of machining operations allows to develop strategies to modify and improve the surface integrity of manufactured components and thereby enhancing their performance and lifetime. These control strategies require reliable real-time data like cutting forces, process temperatures and tool wear. In this work, a wear-resistive thin-film sensor is developed to measure temperature of the cutting tool surface during machining. A multi-layer sensor system is applied on the tool surface by physical vapor deposition (PVD). The tool-sensors are subsequently tested for their functionality and durability in turning operations of AISI 4140q&t steel.