Thin-Film Sensor-Integrated Smart Cutting Tools for Real-Time Machining Temperature Measurement in Industry 4.0

¹ Department of Mechanical Engineering, Shree Venkateshwara Hi-Tech Engineering College, Gobichettipalayam 638455, Tamil Nadu, India
² Department of Automobile Engineering, Rajalakshmi Engineering College, Chennai 602105, Tamil Nadu, India
^3,7 Department of Mechanical Engineering, Nandha College of Technology, Perundurai 638052, Tamil Nadu, India.
⁴ Department of Naval Architecture and Offshore Engineering, Academy of Meritime Education and Training, Chennai 603112, Tamil Nadu, India
⁵ Retired Principal, St Aloysius College, Thrissur 680611, Kerala, India
⁶ Department of Mechanical Engineering, PSG Institute of Technology and Applied Research, Coimbatore 641062, Tamil Nadu, India

^* Corresponding author: This email address is being protected from spambots. You need JavaScript enabled to view it.

Published online: 3 March 2026

Abstract

This research delves into the incorporation of thin-film sensors made of zirconium aluminum nitride (ZrAlN) and titanium aluminum nitride (TiAlN) into cutting tools to track the temperature of Ti6Al4V titanium alloy as it is being machined in real-time. The sensors were calibrated for temperatures up to 750℃ and then deposited directly onto the surfaces of the tools. The coatings included many layers that served to shield the tools from electrical currents and wear. The sensors show varying β sensitivities spanning a temperature range of 928 to 6680 K for ZrAlN and from 112 to 825 K for TiAlN, as a result of being integrated into the multilayer coating. Cutting temperature was found to be affected by cutting conditions, feed rate, depth of cut, and cooling, according to cutting tests performed under different cutting settings. Our research shows that determining the cutting temperature relies heavily on where the sensor is located on the tool's rake face. In a “plug-and-play” form that is compatible with industry standards, the study presents a new tool connector that allows for the integration and signal retrieval of the cutting tool. Smart cutting tools enable real-time, in- situ temperature monitoring by wireless transfer, supporting Industry 4.0 integration in modern manufacturing.