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Updated: Aug 22, 2025

Design and Application of a Fault Detection Method Based on Adaptive Filters and Rotational Speed Estimation for an Electro-Hydrostatic Actuator

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Development of Online Tool Wear-Out Detection System Using Silver-Polyester Thick Film Sensor for Low-Duty Cycle

Jegadeeshwaran Rakkiyannan¹, Lakshmipathi Jakkamputi², Mohanraj Thangamuthu³

¹Center for Automation, School of Mechanical Engineering, Vellore Institute of Technology, Chennai 600127, India.

Sensors (Basel, Switzerland)

|November 11, 2022

Summary

A novel silver-polyester thick film sensor offers a simple, reliable method for detecting cutting tool wear in real-time during low-duty machining. This system overcomes limitations of conventional methods, enhancing operational efficiency and safety.

Keywords:

low-duty cycle polyester substrate single point cutting tool thick film sensor wear-out detection

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Experimental Multiscale Methodology for Predicting Material Fouling Resistance

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Area of Science:

Materials Science
Mechanical Engineering
Manufacturing Technology

Background:

Conventional tool wear detection methods (dynamometers, accelerometers, acoustic emission sensors, thermal cameras, machine vision) have limitations, including process interference.
Direct optical measurements, while accurate, can disrupt the machining process.
Existing methods are often complex and may not be suitable for real-time, low-duty cycle operations.

Purpose of the Study:

To design and develop a silver-polyester thick film sensor system for real-time cutting tool wear-out detection.
To address the limitations of conventional tool wear monitoring techniques in low-duty cycle machining.
To evaluate the sensor's performance and reliability in detecting tool wear directly.

Main Methods:

Development of a silver-polyester thick film sensor integrated directly onto the cutting tool tip.
Real-time monitoring of tool condition as wear directly impacts the sensor.
Investigation of the sensor's response to tool temperature variations during machining.

Main Results:

The proposed thick film sensor system accurately detects tool wear in real-time.
The sensor's direct interaction with wear simplifies the system, enhancing reliability.
Analysis confirmed the sensor's performance across different service temperatures, considering substrate deformation.

Conclusions:

The silver-polyester thick film sensor system is a highly capable and reliable solution for detecting cutting tool wear.
This approach offers a simpler and more robust alternative to conventional tool wear monitoring systems.
The developed sensor is suitable for real-time, low-duty cycle machining operations, improving process control.