Process control Sensing changes in machining of materials

The Temperchip machining temperature sensor provides real time machining data that protects workpieces, allows users to meet stringent specification requirements and enables optimal utilization of cutting tools.

In machining, tool life is often judged by experience rather than real-time process data — a gap that Temperchip aims to close with contactless temperature monitoring directly at the workpiece contact zone. The technology provides real-time visibility and warns operators before workpieces overheat, helping to prevent material damage and production losses. Understanding and predicting tool life is a crucial factor in machining. By accurately monitoring the temperature in the workpiece contact zone, the patented device supports machine performance and contributes to more efficient machining.

When working with cutting tools, machine operators can often only roughly estimate tool life. Tool vendors may provide tool-life data, but this information is frequently generalized and may be inaccurate because of the wide variety of cutting tool applications. A new development is now emerging to support machinists seeking more reliable process data.

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Temperchip is a contactless temperature measurement device for machining applications that is installed on machine holders. The patented device is designed for machining various materials and enables continuous temperature monitoring during the process. It can track several work parameters between the machine and the work material, providing a basis for monitoring tool life and machining efficiency.

Temperchip originated as a response to a series of overheating problems that occurred during the cutting of composite materials, particularly carbon fiber-reinforced polymers (CFRP), and metallic alloys specified for a major commercial aircraft program. The main cause of tool failure was identified as uncontrolled temperature during the milling and cutting process.

Advancing the idea into development took time. Around 12 months later, the first prototype device was ready for testing. In addition to the Temperchip device, a dedicated software application with a graphical user interface was developed to communicate with the device, interpret the measured signals as temperature data and predict the maximum tool and material temperature.

This was followed by field tests comparing ambient temperature with the highest signals measured during validation.

Estimating the performance life of a tool can lead to operational challenges. In many cases, the decision to replace a tool depends on the machine operator’s judgement. This creates the risk of human error, with tools being replaced either too early or too late.

Temperchip addresses this issue with a design that includes interactive communication functions. Operators can be alerted by red LED lights, a smartphone application and/or the machine control system. The device consists of various sensors, a miniature battery, an electronic control board, a BLE communication chip and a recharge chip.

The measurement device can also be calibrated according to critical points, typically 10 to 15 percent below the limits at which damage may be expected. Calibration is carried out according to the work specimen and/or workpiece material type.

For example, the glass transition temperature (Tg) of carbon fiber-reinforced polymer (CFRP) can cause a loss of mechanical properties, while delamination may occur at around 130°C. Under these conditions, the device would be calibrated to approximately 110 to 115°C.

Based on the data collected by the Temperchip device, operators can adjust the machine’s working parameters, stop the operation or replace the tool as needed. The available measurement parameters include process temperature, load and torque, vibrations and cutter wear.

When the machining process reaches the defined threshold points, an LED light on the device warns the operator. The operator can then stop the machine manually or replace the tool.

Optionally, the machine can receive communication transmitted by the device and initiate preventive measures such as tool replacement via the magazine, feed-rate reduction, spindle-speed reduction or chip-load reduction. In line with Industry 4.0 principles, the machine controller can be programmed with algorithms that apply the most efficient preventive step according to the specific scenario.

By providing reliable data on tool performance when cutting composite materials, Temperchip gives machine operators the evidence needed to predict tool life more accurately. It also helps reduce production costs, supports high-efficiency tool use and can reduce the need for a separate tool-life validation process.

* *Eli Yudkevich is an aerospace manufacturing specialist.

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