Development of Cutting Tools with Built-in Thin Film Thermocouple for Monitoring Machining Temperature

2011 ◽  
Vol 189-193 ◽  
pp. 3170-3174
Author(s):  
Qi Yong Zeng ◽  
Xiao Feng Zheng ◽  
Gao Hui Zhang ◽  
Le Chen
Keyword(s):  
Thin Film ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Vital Role ◽  
Polycrystalline Cubic Boron Nitride ◽  
Thin Film Thermocouple ◽  
Thin Film Thermocouples ◽  
Pcbn Tools ◽  
Deposition Conditions

Temperature plays a vital role in the machining industry today. NiCr/NiSi thin-film thermocouples have been deposited on the rake face of polycrystalline cubic boron nitride (PCBN) tools by magnetron sputtering. The typical deposition conditions are summarized. Static and dynamic calibrations of the NiCr/NiSi thin-film thermocouples are presented. The Seebeck coefficient of the TFTC is 37.3 μV/°C. The response time is about 3.9 ms. The testing results indicate that the developed NiCr/NiSi thin-film thermocouple sensors perform excellently when machining A3 steel in situ.

High Precision Cutting and High Speed Interrupted Cutting of Hardened Steel With PCBN Tools

1999 ◽  
Author(s):  
Katsuhito Yoshida ◽  
Satoru Kukino ◽  
Takashi Harada ◽  
Tomohiro Fukaya ◽  
Junichi Shiraishi ◽  
...  
Keyword(s):  
High Precision ◽  
High Speed ◽  
New Technologies ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Hardened Steel ◽  
Precision Machining ◽  
Polycrystalline Cubic Boron Nitride ◽  
Interrupted Cutting ◽  
Pcbn Tools

Abstract PCBN (Polycrystalline Cubic Boron Nitride) cutting tools have become very familiar in the industries for cutting hardened steel parts and the demand for PCBN tools is growing rapidly. One of the reasons for this is the trend of replacing grinding processes with cutting. Although the trend of processing is to use more cutting, there still remains grinding in many processing fields. High precision machining and high speed interrupted machining have been such fields. In this study it has been verified that a novel cutting method can be applied to high precision machining with the smoothness of Rz 0.8 μm and that a new PCBN has sufficient reliability against tool failure in high speed (< 250m/min) interrupted cutting. Thus cutting has become applicable to those machining and the trend of replacement of grinding with cutting will be enhanced. Those new technologies will be introduced in this report.

scholarly journals Indium Tin Oxide Thin-Film Thermocouple Probe Based on Sapphire Microrod

Sensors ◽  
2020 ◽  
Vol 20 (5) ◽  
pp. 1289 ◽  
Author(s):  
Jinjun Deng ◽  
Linwei Zhang ◽  
Liuan Hui ◽  
Xinhang Jin ◽  
Binghe Ma
Keyword(s):  
Thin Film ◽  
Tin Oxide ◽  
Indium Tin Oxide ◽  
Gas Turbines ◽  
Oxide Thin Film ◽  
Main Challenge ◽  
Thin Film Thermocouple ◽  
Thin Film Thermocouples ◽  
Thermocouple Probe

Indium tin oxide (ITO) thin-film thermocouples monitor the temperature of hot section components in gas turbines. As an in situ measuring technology, the main challenge of a thin-film thermocouple is its installation on complex geometric surfaces. In this study, an ITO thin-film thermocouple probe based on a sapphire microrod was used to access narrow areas. The performance of the probe, i.e., the thermoelectricity and stability, was analyzed. This novel sensor resolves the installation difficulties of thin-film devices.

Micro Thin Film Temperature Sensors Embedded in Metal Structures

2004 ◽  
Author(s):  
Hongseok Choi ◽  
Arindom Datta ◽  
Xiaochun Li
Keyword(s):  
Thin Film ◽  
Chemical Vapor ◽  
Temperature Sensors ◽  
In Situ Monitoring ◽  
Manufacturing Processes ◽  
Metal Structures ◽  
Thin Film Sensors ◽  
Thin Film Thermocouple ◽  
Thin Film Thermocouples

This paper studies the fabrication and calibration of thin film temperature sensors embedded in metal structures. Thin film thermocouples have been successfully fabricated on various metal substrates and advanced embedding techniques have been developed to ensure sensor function inside metal structures. Thin film thermocouple was insulated with multiple thin film layers (Al2O3 and Si3N4) by e-beam evaporating and plasma enhanced chemical vapor deposition (PECVD). The sensors are calibrated. These embedded thin film sensors provide superior spatial and temporal resolution that is not possible with traditional sensors used in various manufacturing processes. This research is significant in a way that it provides a new and improved route for in-situ monitoring of manufacturing process.

Magnetron Sputtering of NiCr/NiSi Thin-Film Thermocouple Sensor for Temperature Measurement when Machining Chemical Explosive Material

2011 ◽  
Vol 467-469 ◽  
pp. 134-139 ◽  
Author(s):  
Qi Yong Zeng ◽  
Tao Hong ◽  
Le Chen ◽  
Yun Xian Cui
Keyword(s):  
Thin Film ◽  
Magnetron Sputtering ◽  
High Speed ◽  
High Speed Steel ◽  
Vital Role ◽  
Explosive Material ◽  
Silicon Thin Film ◽  
Thin Film Thermocouple ◽  
Thin Film Thermocouples ◽  
Nickel Silicon

Temperature plays a vital role in the machining industry today. A Nickel-Chrome versus Nickel-Silicon thin-film thermocouple system has been established for measuring instantaneous workpiece temperature in chemical explosive material machining. The NiCr/NiSi thin-film thermocouples have been deposited inside high speed steel cutters by magnetron sputtering. The typical deposition conditions are summarized. Static and dynamic calibrations of the NiCr/NiSi thin-film thermocouples are presented. The Seebeck coefficient of the TFTC is 40.4 μV/°C which is almost the same as that of NiCr/NiSi wire thermocouple. The response time is about 0.42ms. The testing results indicate that the developed NiCr/NiSi thin-film thermocouple sensors can respond fast enough to catch the very short temperature pulse and perform excellently when machining chemical explosive material in situ.

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

2013 ◽  
Vol 135 (4) ◽  
Author(s):  
Linwen Li ◽  
Bin Li ◽  
Xiaochun Li ◽  
Kornel F. Ehmann
Keyword(s):  
Thin Film ◽  
Hard Turning ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Cutting Insert ◽  
Thin Film Thermocouples ◽  
Cutting Zone

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 μm) 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.

Metallurgical Study of Friction Stir Welded High Strength Steels for Shipbuilding

2014 ◽  
Vol 783-786 ◽  
pp. 2798-2803 ◽  
Author(s):  
Marion Allart ◽  
Alexandre Benoit ◽  
Pascal Paillard ◽  
Guillaume Rückert ◽  
Myriam Chargy
Keyword(s):  
Cubic Boron Nitride ◽  
High Strength Steels ◽  
High Strength ◽  
High Yield ◽  
Friction Stir ◽  
Polycrystalline Cubic Boron Nitride ◽  
Recent Developments ◽  
Metallurgical Study ◽  
Welding Processes ◽  
Pcbn Tools

Friction Stir Welding (FSW) is one of the most recent welding processes, invented in 1991 by The Welding Institute. Recent developments, mainly using polycrystalline cubic boron nitride (PCBN) tools, broaden the range of use of FSW to harder materials, like steels. Our study focused on the assembly of high yield strength steels for naval applications by FSW, and its consequences on the metallurgical properties. The main objectivewas to analyze the metallurgical transformations occurring during welding. Welding tests were conducted on three steels: 80HLES, S690QL and DH36. For each welded sample, macrographs, micrographs and micro-hardness maps were performed to characterize the variation of microstructures through the weld.

scholarly journals Technics Research on Polycrystalline Cubic Boron Nitride Cutting Tools Dry Turning Ti-6AL-4V Alloy Based on Orthogonal Experimental Design

2018 ◽  
Vol 142 ◽  
pp. 03002
Author(s):  
Yunhai Jia ◽  
Lixin Zhu
Keyword(s):  
Surface Roughness ◽  
Experimental Design ◽  
Boron Nitride ◽  
Feed Rate ◽  
Flank Wear ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Orthogonal Experimental Design ◽  
Polycrystalline Cubic Boron Nitride

Ti-6Al-4V components are the most widely used titanium alloy products not only in the aerospace industry, but also for bio-medical applications. The machine-ability of titanium alloys is impaired by their high temperature chemical reactivity, low thermal conductivity and low modulus of elasticity. Polycrystalline cubic boron nitride represents a substitute tool material for turning titanium alloys due to its high hardness, wear resistance, thermal stability and hot red hardness. For determination of suitable cutting parameters in dry turning Ti-6AL-4V alloy by Polycrystalline cubic boron nitride cutting tools, the samples, 300mm in length and 100mm in diameter, were dry machined in a lathe. The turning suitable parameters, such as cutting speed, feed rate and cut depth were determined according to workpieces surface roughness and tools flank wear based on orthogonal experimental design. The experiment showed that the cutting speed in the range of 160~180 m/min, the feed rate is 0.15 mm/rev and the depth of cut is 0.20mm, ideal workpiece surface roughness and little cutting tools flank wear can be obtained.

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