Scopus İndeksli Yayınlar Koleksiyonu
Permanent URI for this collectionhttps://hdl.handle.net/20.500.12573/395
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Article Minimization of Thermal Stresses in Instrumented Cutting Tools with Embedded Thin Film Thermocouples(Korean Society of Mechanical Engineers, 2026-04) Kesriklioglu, Sinan; Sivesoglu, AbdurrahmanThis study investigates the optimization of multilayer coatings on cutting tools to minimize thermal stress and temperature differences between the tool-chip interface and embedded thermocouples. The novelty of this study lies in directly linking coating architecture to temperature measurement accuracy, revealing that coatings not only affect heat dissipation and stress development but may also distort the apparent temperature recorded by embedded sensors. The types and thickness ranges of thin film layers in instrumented cutting tools were determined, and multi-physics finite element simulations were then used to evaluate coating configurations under thermal loading, assessing both stress distribution and temperature variance in the multilayer coating system. The Taguchi method, coupled with desirability analysis, identified optimal coating parameters that simultaneously minimize thermal stresses and temperature disparities, which are critical for accurate temperature measurements and extending the lifespan of cutting inserts. This framework enables a controllable trade-off between mechanical reliability and thermal measurement fidelity. The results reveal significant interactions among coating configurations (settings) and between thermal and mechanical properties of the materials used, demonstrating that careful selection of layer materials and thicknesses optimizes stress and temperature responses yielding thermal stress of 1628 MPa (second lowest and only 0.4 % higher than the minimum) and temperature difference of 12.1 degrees C (third lowest and 55 % lower than average). These findings underscore the potential of precise coating design to enhance tool performance and longevity in high temperature machining applications.Article Citation - WoS: 5Citation - Scopus: 5Ineffectiveness of Flood Cooling in Reducing Cutting Temperatures During Continuous Machining(Springer London Ltd, 2022-09-19) Kesriklioglu, SinanWater-based metalworking fluids are applied in the form of a liquid jet to flood the entire cutting zone and increase the tool life. The objective of this study is to investigate the effectiveness of flood cooling in reducing the tool chip interface temperatures during continuous cutting. An instrumented smart cutting tool with a thin film temperature sensor was fabricated to accurately measure the real-time cutting temperatures from 1.3 mu m below the tool chip interface in orthogonal turning of AISI 4140 steel under dry and flood cooling conditions. The cutting process was simulated in Deform 2D with the Johnson-Cook material model to present the transient temperature distributions on the coated cutting insert. The heat flux into the cutting tool was also estimated analytically and then three-dimensional finite element heat transfer simulations were performed to determine the maximum convective heat transfer of the cutting fluid in steady state. The measurements with the embedded thermocouple showed that flood cooling with a water-based cutting fluid slightly lowers the tool chip interface temperature. Moreover, the chip color may not be a good characteristic indicator to evaluate the cutting temperature in machining of metals. It was also found that flood cooling becomes more effective at a distance of approximately 150 mu m from the cutting edge where the chip does not contact the rake face of the cutting tool.