The objective of this work is to fabricate thermocouples directly on the rake face of a commercially available tungsten carbide cutting insert for accurately measuring the tool–chip interface temperature during metal cutting. The thermocouples are sputtered onto the cutting insert using micromachined stencils, are electrically isolated with layers of Al2O3, and receive a top coating of AlTiN for durability. The result is a nonsacrificial thermocouple junction that is approximately 1.3 µm below the rake face of the tool and 30 µm from the cutting edge. Experimental and numerical characterization of the temperature measurement accuracy and response time are presented. The instrumented cutting tool can capture the tool–chip interface temperature transients at frequencies of up to 1 MHz, which enables the observation of serrated chip formation and adiabatic shear events. Temperature measurements from oblique machining of 4140 steel are presented and compared with three-dimensional, transient numerical simulations using finite element analysis, where cutting speed and feed are varied. This method of measuring the tool–chip interface temperature shows promise for future research and smart manufacturing applications.
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September 2019
Research-Article
Characterization of Tool–Chip Interface Temperature Measurement With Thermocouple Fabricated Directly on the Rake Face
Sinan Kesriklioglu,
Sinan Kesriklioglu
Department of Mechanical Engineering,
Madison, WI 53706
e-mail: sinankesriklioglu@gmail.com
University of Wisconsin-Madison
,Madison, WI 53706
e-mail: sinankesriklioglu@gmail.com
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Justin D. Morrow,
Justin D. Morrow
Department of Mechanical Engineering,
Madison, WI 53706
e-mail: justin.morrow6@gmail.com
University of Wisconsin-Madison
,Madison, WI 53706
e-mail: justin.morrow6@gmail.com
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Frank E. Pfefferkorn
Frank E. Pfefferkorn
1
Department of Mechanical Engineering,
Madison, WI 53706
e-mail: frank.pfefferkorn@wisc.edu
University of Wisconsin-Madison
,Madison, WI 53706
e-mail: frank.pfefferkorn@wisc.edu
1Corresponding author.
Search for other works by this author on:
Sinan Kesriklioglu
Department of Mechanical Engineering,
Madison, WI 53706
e-mail: sinankesriklioglu@gmail.com
University of Wisconsin-Madison
,Madison, WI 53706
e-mail: sinankesriklioglu@gmail.com
Cory Arthur
Justin D. Morrow
Department of Mechanical Engineering,
Madison, WI 53706
e-mail: justin.morrow6@gmail.com
University of Wisconsin-Madison
,Madison, WI 53706
e-mail: justin.morrow6@gmail.com
Frank E. Pfefferkorn
Department of Mechanical Engineering,
Madison, WI 53706
e-mail: frank.pfefferkorn@wisc.edu
University of Wisconsin-Madison
,Madison, WI 53706
e-mail: frank.pfefferkorn@wisc.edu
1Corresponding author.
Manuscript received July 3, 2018; final manuscript received May 24, 2019; published online July 22, 2019. Assoc. Editor: Tugrul Ozel.
J. Manuf. Sci. Eng. Sep 2019, 141(9): 091008 (9 pages)
Published Online: July 22, 2019
Article history
Received:
July 3, 2018
Revision Received:
May 24, 2019
Accepted:
May 26, 2019
Citation
Kesriklioglu, S., Arthur, C., Morrow, J. D., and Pfefferkorn, F. E. (July 22, 2019). "Characterization of Tool–Chip Interface Temperature Measurement With Thermocouple Fabricated Directly on the Rake Face." ASME. J. Manuf. Sci. Eng. September 2019; 141(9): 091008. https://doi.org/10.1115/1.4044035
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