Wear sensor integrated cutting tool for turning

An in-process tool wear meter for turning has been developed by combining a sensor-integrated insert and simple signal processing technique. The sensor consists of TiN thin lines, which are deposited on the flank of each cutting corner of ceramic insert in parallel with the edge. As flank wear causes breakage of the lines, a step increase in sensor resistance occurs. This feature of the resistance signal ensures easy and reliable interpretation of the sensor resistance output in terms of flank wear amount. An appropriate processing technique for the signal interpretation is developed on the basis of non-linear median filtration. The sensor-integrated insert shows the same characteristics of mechanical, electrical, temperature properties as those of conventional inserts.