Development of Cutting Tool With Built-In Thin Film Thermocouples for Measuring High Temperature Fields in Metal Cutting Processes

Shinozuka, Jun; Basti, Ali; Obikawa, Toshiyuki

doi:10.1115/1.2823066

Cited by 22 publications

(21 citation statements)

References 10 publications

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“…The difference in the temperature gradient by the difference in the cutting speed, however, disappears in the region away from the location that marked the maximum temperature. The indexable insert with seven pairs of built-in micro Cu/Ni thermocouples is able to obtain the temperatures at different seven points simultaneously, providing more clear shape of the temperature distribution at the tool-chip interface than the previous tool with built-in TFTs [2,3]…”

Section: Temperature Measurement Experimentsmentioning

confidence: 99%

“…Though many techniques for grasping the temperature on the tool surface have been proposed so far, the technique of direct measurement is few [1][2][3][4][5]. The author has developed a cutting tool with built-in thin film thermocouples (TFTs) for measuring the temperatures at the tool-chip interface directly [2,3]. For our tool with built-in TFTs, it was difficult to grasp the shape of the temperature distribution clearly, because the numbers of thermocouples were three at maximum.…”

Section: Introductionmentioning

confidence: 99%

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Measurement of the Temperature Distribution at the Tool-Chip Interface by Using a Cutting Tool with Seven Pairs of Built-In Micro Cu/Ni Thermocouples

Shinozuka

Jaharadak

2016

AMR

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Knowing temperatures at the tool-chip interface is extremely important to optimize the machining condition and to improve the machining performance, furthermore to design high performance materials. In order to grasp the temperature distribution at the tool-chip interface, this study has devised an indexable insert with seven pairs of built-in micro Cu/Ni thermocouples on the rake face near the cutting edge. This paper shows the performance of the indexable insert with built-in micro thermocouples developed. The thickness of each element of the micro thermocouple is approximately 15 μm. The result of unsteady heat conduction analysis employing FEM shows that the temperature difference by installing the micro thermocouples is less than 10 K or 1.2 %. The temperature measurement experiments by cutting of aluminum alloy were carried out by changing the cutting speed. The results provided the evidence that the temperature distribution at the tool-chip interface can be grasped with the indexable insert with built-in micro thermocouples developed.

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Section: Temperature Measurement Experimentsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Measurement of the Temperature Distribution at the Tool-Chip Interface by Using a Cutting Tool with Seven Pairs of Built-In Micro Cu/Ni Thermocouples

Shinozuka

Jaharadak

2016

AMR

Self Cite

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“…However, there is also a need for thin film thermocouples in production processes. Therefore, different thin film thermocouples are currently developed for several applications, such as welding [5] or metal [6][7][8][9] and polymer processing [10,11]. However, the thin film thermocouples must be adapted to the respective application fields.…”

Section: Introductionmentioning

confidence: 99%

“…According to DIN EN 60584, eight different thermocouple pairs are available, whereas Fe-CuNi [12], Cu-CuNi [13], NiCr-Ni [6][7][8][9] and Pt-10%Rh/Pt [14] are the most reported thin film thermocouples deposited by means of PVD. Apart from the standardized thermocouples, TiC-TaC [15], Al-Au [11], Ni-Cu [12,16], Ni-Fe [12], Cu-Fe [12], Chromel-Alumel [5,12], and Pt-Pd [4] thin film thermocouples are synthesized.…”

Section: Introductionmentioning

confidence: 99%

Combining Thermal Spraying and Magnetron Sputtering for the Development of Ni/Ni-20Cr Thin Film Thermocouples for Plastic Flat Film Extrusion Processes

et al. 2019

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In the digitalization of production, temperature determination is playing an increasingly important role. Thermal spraying and magnetron sputtering were combined for the development of Ni/Ni-20Cr thin film thermocouples for plastic flat film extrusion processes. On the thermally sprayed insulation layer, AlN and BCN thin films were deposited and analyzed regarding their structural properties and the interaction between the plastic melt and the surfaces using Ball-on-Disc experiments and High-Pressure Capillary Rheometer. A modular tool, containing the deposited Ni/Ni-20Cr thin film thermocouple, was developed and analyzed in a real flat film extrusion process. When calibrating the thin film thermocouple, an accurate temperature determination of the flowing melt was achieved. Industrial type K sensors were used as reference. In addition, PP foils were produced without affecting the surface quality by using thin film thermocouples.

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“…Embedded micro TFTC sensors due to their micro-size dimensions offer a very high temporal and high spatial resolution and the ability to simultaneously record, in real-time, temperatures at and near the cutting zone [9][10][11][12][13][14][15]. The spatial-and/or temporal-resolution of TFTC sensor arrays depends on junction size and the relative distance between sensing junctions.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation of Hard Turning Mechanisms by PCBN Tooling Embedded Micro Thin Film Thermocouples

et al. 2013

Journal of Manufacturing Science and Engineering

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Temperature-distribution measurements in cutting tools during the machining process are extremely difficult and remain an unresolved problem. In this paper, cutting temperature distributions were measured by thin film thermocouples (TFTCs) embedded into polycrystalline cubic boron nitride (PCBN) cutting inserts in the immediate vicinity of the tool-chip interface. The embedded TFTC array provides temperature measurements with a degree of spatial resolution (100 ßm) and dynamic response (150 ns) that is not possible with currently employed methods due to the micro-scale junction size of the TFTCs. Using these measurements during hard turning, steady-state, dynamic, as well as chip morphology and formation process analyses were performed based on the cutting temperature and cutting force variations in the cutting zone. It has been shown that the temperature changes in the cutting zone depend on the shearing band location in the chip and the thermal transfer rate from the heat generation zone to the cutting tool. Furthermore, it became evident that the material flow stress and the shearing bands greatly affect not only the chip formation morphology but also the cutting temperature field distributions in the cutting zone of the cutting insert.

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Development of Cutting Tool With Built-In Thin Film Thermocouples for Measuring High Temperature Fields in Metal Cutting Processes

Cited by 22 publications

References 10 publications

Measurement of the Temperature Distribution at the Tool-Chip Interface by Using a Cutting Tool with Seven Pairs of Built-In Micro Cu/Ni Thermocouples

Measurement of the Temperature Distribution at the Tool-Chip Interface by Using a Cutting Tool with Seven Pairs of Built-In Micro Cu/Ni Thermocouples

Combining Thermal Spraying and Magnetron Sputtering for the Development of Ni/Ni-20Cr Thin Film Thermocouples for Plastic Flat Film Extrusion Processes

Experimental Investigation of Hard Turning Mechanisms by PCBN Tooling Embedded Micro Thin Film Thermocouples

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