Abstract
Smart tools instrumented with thin film thermocouples for online cutting temperature measurement are promising in intelligent manufacturing. However, the surface-mounted planar devices are easily damaged through delamination and abrasion due to the high temperature, great stresses and harsh friction. This paper reports a novel approach to embed the thin film thermocouples in vertical direction to the tool rake face for protection. Attention is also paid to improve the quality of the vertically deposited thin films on the lateral walls of the micro-grooves. Experimental tests have been done to obtain the sensitivity and response of the sensors in the tool. The embedded sensors function well in monitoring the cutting temperature in cutting tests of a titanium alloy.
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