Wear-compensating machining of nanocrystalline surface layers through spatially resolved measurement of temperature and wear

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The aim of this research project is qualifying of in-process capable control of turning enabling machining of defined nanocrystalline surface layers on AISI4140, automatically compensating for wear. This will be achieved by thin film sensor systems applied to the tools surface. These sensors permit spatially resolved measurement of temperature and wear. Additionally, the cutting forces will be measured with an integrated thin film sensor. Using a process model, a softsensor will be built based on the signals of the sensors. This will supply correlations of process control variables and the thermo-mechanical loading with the nanocrystalline surface layer and its thickness. Integration of the softsensor in the tool and the adaption of cutting velocity and feed will then be used to control the surface layer state. Therefore, it will be possible to adjust tribological behavior as well as fatigue life of parts.