Contactless and continuous monitoring of the thermo-mechanical load profiles of protective coatings in the manufacturing technology by integrated ferromagnetic thin films

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The present project proposal aims at wear resistant films with integrated and established ferromagnetic films as a film composite on hard metal substrates (cutting inserts as a tool for metal cutting) with a sensor function for industrial applications. By it the exposure profile of the wear resistant film or tool ought to be continuously controlled during a turning process in production technology. In order to realise data compilation, a sensor measuring head (high-frequency coil) will be refined which records changes of the susceptibility or permeability through changes of the magnetic properties due to the temperature evolution within a distance of a few millimetres in a non-contact mode. At this point, the magnetoelastic properties in connection with the induced film stress, i.e., also changes of the magnetic film anisotropy as well as the temperature dependent magnetisation which interact with the sensor sensitivity, play a crucial role. By means of these data the correlation with the tool status such as wear will be elaborated. One of the challenges, among others, is to miniaturise the measuring head and to approach it to the cutting edge as close as possible by simultaneously adapting it to the entire tool system. As a result a model system representing a demonstrator under real cutting- and ambient conditions (mounting, lubricant and coolant) will serve as a basis for an optional product development.