Development of a novel surface acoustic wave (SAW) based smart cutting tool in machining hybrid dissimilar material

This paper presents the design of an innovative surface acoustic wave (SAW)-based smart cutting tool for high value machining. Two SAW sensors are mounted onto two Aluminium plates bolted on top and bottom of the cutting tool shank respectively, to measure cutting force. A hybrid dissimilar material made of two different materials welded together as a single bar is machined using the SAW-based cutting tool; this can be used to simulate an abrupt change in material properties. The property transition zone is successfully detected by the tool; the sensor feedback can be used to provoke a change in the machining parameters to compensate altered material properties.