In-situ characterization of tool temperatures using in-tool integrated thermoresistive thin-film sensors

Germán González, Marcel Plogmeyer, Julius Schoop, Günter Bräuer, Volker Schulze

Research output: Contribution to journalArticlepeer-review


Metal cutting is characterized by high temperatures at the tool-workpiece interface. Although valuable information could be provided by the temperature values, their direct measurement still presents a challenge due to the high contact pressure and the inaccessibility of the process kinematic. In this research work, the current state of thin-film sensors for measuring temperatures on the chip-tool interface has been analyzed with a focus on the measuring phenomena: thermoelectricity and thermoresistivity. Thin-film sensors placed on the cutting tools in or close to the tool-chip contact area are expected to obtain accurate temperature information at the expense of a short lifetime. New insights into thin-film sensors manufacturing, design and calibration are presented, and a new concept of a three-point thermoresistive thin-film sensor is proposed. During orthogonal cutting tests the workpiece deformations were measured through high-speed imaging and the process temperatures were measured with thin-film sensors. In order to validate the temperatures and to obtain the temperature distribution on the cutting edge, Finite Element simulations were carried out. Finally, the potential of using cutting tools with integrated thin-film sensors for in-situ characterization is investigated and a statement for its limitations and potential applications is given.

Original languageEnglish
Pages (from-to)319-328
Number of pages10
JournalProduction Engineering
Issue number2
StatePublished - Apr 2023

Bibliographical note

Funding Information:
The authors gratefully acknowledge the financial support of the the Karlsruhe House of Young Scientists (KHYS) and the German Research Foundation, Deutsche Forschungsgemeinschaft (DFG) within the research priority program SPP2086 ”Surface Conditioning in machining” SCHU 1010/63-2 and BR 2178/47-2, with the project number 401538720.

Publisher Copyright:
© 2023, The Author(s).


  • High-speed imaging
  • Orthogonal cutting
  • Temperature measurement
  • Thin-film sensor

ASJC Scopus subject areas

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering


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