A homemade NiCr/NiSi thin-film thermocouple integrated with a PCBN turning tool was developed for real-time temperature monitoring during dry turning of AISI 1045 steel. The study addresses a practical limitation of existing cutting-temperature methods, namely the difficulty of combining local in situ sensing near the cutting edge with a transient thermal analysis framework that can interpret the measured signal under repeatable cutting conditions. The sensor was fabricated on an Al2O3 substrate by magnetron sputtering, protected by a SiO2 layer, and tested at cutting speeds corresponding to spindle speeds of 1000, 1500 and 2000 rpm, with a cutting depth of 0.5 mm, a feed rate of 0.1 mm/rev and cutting times of 30–90 s. A three-dimensional transient heat-conduction model and inverse heat-flux reconstruction were then used to interpret the temperature history. The maximum measured temperature increased from 342 °C to 488 °C, and VB increased from 0.082 mm to 0.295 mm, showing a strong temperature–wear association within the investigated parameter window.
Luo et al. (Thu,) studied this question.
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