A new design of boron-doped diamond coated intelligent cutting tool with self-temperature-sensing capability

Real-time cutting temperature monitoring is critical for metal cutting. Contact and non-contact measurement methods both have inherent limitations. This study developed a boron-doped diamond (BDD) coated cemented carbide intelligent tool with self-temperature-sensing capability. The BDD coating was prepared via the HFCVD method. We characterized the microstructural and elemental properties of the coated tool. A precise resistance-temperature calibration of the tool was conducted. A closed-loop signal acquisition and remote monitoring system was designed for the tool. Static and dynamic performance tests verified the tool’s good repeatability and stability. Its dynamic response was comparable to that of a thermocouple. Turning experiments were carried out with aluminum alloy workpieces. The tool’s temperature measurement results were compared with those of a thermocouple and an infrared thermal imager. The results showed high temporal consistency with the thermocouple. The deviation from infrared thermography was less than 5%. The BDD-coated intelligent tool achieves in situ real-time cutting temperature monitoring. It exhibits excellent measurement performance and structural integrity. This design provides a novel approach for intelligent temperature sensing in metal cutting. It also promotes the development of intelligent cutting tools for smart manufacturing.