Abstract Due to harsh environment in the cutting area, access to the cutting region is still limited for the existing temperature sensors. As such, measuring temperature signals remains a challenge for real-time tool wear monitoring. In this paper, a polycrystalline cubic boron nitride (PCBN) cutting tool embedded with thin-film thermocouple (TFTC) was devised and used for tool wear monitoring during the cutting of hardened AISI O2 tool steel. A detailed manufacturing process of the smart tool was introduced. Performance tests for the smart insert were evaluated and results showed that the embedded TFTC had a sensitivity of 14.4 μV/℃, good dynamic response, and functional validity. Wear experiments were implemented under two sets of cutting parameters to explore the relationship between cutting temperature and tool wear. The results showed that the increased maximum cutting temperature could well reflect the progression of flank wear. Obvious fluctuation in temperature signal could also well reflect the abnormal condition of the tool. The devised smart tool will be useful for determining optimum cutting parameters and extending tool life.

中文翻译：

---

使用薄膜热电偶实时监测刀具磨损

摘要 由于切割区环境恶劣，现有温度传感器对切割区的访问仍然受到限制。因此，测量温度信号仍然是实时刀具磨损监测的一个挑战。在本文中，设计了一种嵌入薄膜热电偶 (TFTC) 的多晶立方氮化硼 (PCBN) 刀具，并将其用于切削硬化 AISI O2 工具钢时的刀具磨损监测。介绍了智能工具的详细制造过程。对智能插件的性能测试进行了评估，结果表明嵌入式 TFTC 的灵敏度为 14.4 μV/℃，具有良好的动态响应和功能有效性。在两组切削参数下进行磨损实验，探索切削温度与刀具磨损之间的关系。结果表明，提高的最高切削温度可以很好地反映后刀面磨损的进展。温度信号的明显波动也可以很好地反映工具的异常情况。设计的智能刀具将有助于确定最佳切削参数和延长刀具寿命。