Real-Time Cutting Temperature Measurement in Turning of AISI 1045 Steel through an Embedded Thermocouple—A Comparative Study with Infrared Thermography

Abstract

During machining processes, a high temperature is generated in the cutting zone due to deformation of the material and friction of the chip along the surface of the tool. This high temperature has a detrimental effect on the cutting tool, and for this reason, it is of the utmost importance to assess the cutting temperature in real time during these processes. Despite all the advances and investigation in this field, accurately measuring the cutting temperature remains a great challenge. In this sense, this work intends to contribute to solving this problem by experimentally evaluating the potential of the developed approach for embedding thermocouples into the rake face of cutting tools for measuring cutting temperature in real time during dry turning of AISI 1045 steel for different cutting parameters and comparing the obtained results with infrared thermography measurements at the exact same point. A well-defined, smooth micro-groove with good surface quality was produced by laser surface modification. Then a laser-welded K-type thermocouple was fixated in the micro-groove with a MgO ceramic adhesive, ensuring protection from wear and chips, which allowed the creation of WC-Co cutting inserts with the ability to measure cutting tool temperature with a maximum error of 0.96%. Results showed that, despite yielding the same trend, the tool temperature measured by the IR thermographic camera was always lower than the temperature measured by the K-type embedded thermocouple. The proposed embedded thermocouple method proved to be a reliable, precise, accurate, and cost-effective approach for real-time temperature measurement capable of providing useful information for cutting parameter optimization, thus allowing increased productivity and tool life.

Assessment of performance parameters in intermittent turning and multi-response optimization of machining conditions using DF, MOORA, VIKOR, and coupled NSGAII-VIKOR methods

“…A contribution of 22.59% is observed for the parameter (f), and finally, the factor (r) exhibits a relatively modest contribution percentage of 17.98%. Similar findings have been reported in other research works, indicating that both (ap) and (Vc) directly influence the increase in (Ct) [30][31][32]. The ANOVA applied to (VB) clearly shows that the (Vc) factor occupies a dominant position, with a percentage contribution equal to 66.44%, followed by the (f) factor, which contributes with 25.95%.…”

Standalone Sensors System for Real-Time Monitoring of Cutting Emulsion Properties with Adaptive Integration in Machine Tool Operation

“…This method (monitoring of cutting emulsions in real time) can be included among the so-called Ecologically Friendly Machining (EcoFriM) methods, which include: dry machining [36,37], machining with a minimum amount of cutting fluids and cryogenic machining [38,39], the use of ecological (biodegradable) cutting media [40], and replacing oil with ecologically acceptable cutting emulsions [5], monitoring the properties of cutting fluids to increase their service life while maintaining the sufficient quality of the machined surfaces.…”

Prediction of Isotropic Rough Surface Directional Spectral Emissivity with Surface-Morphology-Dependent Modelling

“…Infrared-related measurement of rough surfaces including sandblasted surfaces and casted surfaces has been widely applied in machining and other metal-related processes in the industry [1][2][3]. An infrared thermometer is introduced for on-time temperature measurement in the dry cutting of AISI 1045 [4]. The results show good coherence with the data measured using thermocouples.…”