Real-Time Cutting Temperature Monitoring and Tool Wear Prediction with Integrated Thin-Film Thermocouples and Coupled
Yingyuan Luo1, Fenghao Zuo2, Binghai Lyu3
1School of Intelligent Manufacturing, Hangzhou Polytechnic, Hangzhou 311402, China.
Micromachines
|June 26, 2026
Summary
This study introduces a novel framework combining thin-film thermocouples and simulations to accurately measure cutting zone temperatures and predict tool wear in machining. The integrated system enhances machining control and tool life prediction.
Area of Science:
- Materials Science
- Mechanical Engineering
- Manufacturing Technology
Background:
- Accurate measurement of cutting zone temperature is critical for closed-loop machining but challenging due to small contact areas and steep thermal gradients.
- Existing methods struggle with the complex thermal environment at the tool-chip interface.
Purpose of the Study:
- To develop an integrated framework for in situ monitoring of cutting temperature and prediction of tool wear.
- To combine a thin-film thermocouple (TFTC) sensor with a thermo-mechanical wear-coupled simulation.
Main Methods:
- Fabrication of a TFTC using magnetron sputtering of NiCr and NiSi films on a polycrystalline cubic boron nitride (PCBN) tool.
- Development of a 3D finite-element turning model with a moving heat source and an enhanced Archard-type wear law.
- Conducting turning experiments on AISI 1045 steel under various cooling conditions (dry, wet, cryogenic).
Main Results:
- The TFTC demonstrated a fast response time (~0.3 s) and high linearity (R² = 1) with temperature, agreeing with infrared measurements within ±3 °C.
- Simulations showed peak rake-face temperature increased nonlinearly with spindle speed (R² = 0.99).
- The coupled wear model accurately replicated wear growth, and cooling reduced thermal loads by up to 25%.
Conclusions:
- The integrated TFTC and simulation framework provides accurate in situ cutting temperature monitoring and reliable tool wear prediction.
- Thermo-mechanical coupling significantly influences wear rates, and cooling strategies are effective in reducing thermal loads.
- This approach offers enhanced control and optimization for machining processes.
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