Tool-integrated thin-film sensor systems for measurement of cutting forces and temperatures during machining

Effective in-process control mechanisms are vital for the future development of production processes and ask for reliable monitoring of process variables. For this, new tool-integrated sensor systems for measuring cutting forces and temperature for machining of hardened steel are proposed. Thin-film technology is used to apply a thermoresistive temperature sensor in the chip-workpiece contact area for the first time on industrial cutting inserts with chip breaker geometry. Complementary piezoresistive thin-film sensors based on diamond-like carbon (DLC) and manganin layers were developed and deposited on a washer. It was placed beneath the indexable insert to measure the cutting forces. Turning experiments were conducted to study sensor life and accuracy. All sensors showed an adequate lifetime for laboratory purposes. Temperature compensation methods were investigated for force measurement and results compared to forces recorded by a dynamometric platform. While temperature compensation for the DLC-based sensor needs further optimization, results of the manganin-based sensor compared well with the expected cutting forces. The manganin thin-film sensor exhibited rapid responsiveness and great reproducibility, underscoring its prospective utility for real-time monitoring of cutting forces in machining operations.