Fabrication of smart cutting tools with embedded optical fiber sensors using combined laser solid freeform fabrication and moulding techniques

To realize the concept of smart tools, embedding of fiber optic sensors in the metallic structure of a cutting tool with combined laser solid freeform fabrication (LSFF) and moulding is presented in this paper. Metallic parts with embedded optical fiber sensors are capable of monitoring physical parameters like force and temperature. These sensors are advantageous relative to other conventional electric and electromagnetic sensors due to their light weight, immunity to external electromagnetic fields, small size, long-term durability, and long-range linearity. In the present work, the optical fibers (e.g., fiber Bragg grating sensor, single-mode fiber optics) are moulded under tensile forces within a mild steel casing filled by Sn–Pb to fabricate a protective layer around them. Afterwards, LSFF is utilized to deposit tungsten carbide reinforced in cobalt (WC–Co) on the surface of the mild steel component. The performance results, in which the sensor exposed to a light bandwidth, show that the maximum light power loss after embedding is about 21% implying that the fiber is not damaged during the embedding process. Also, the sensor output has a linear characteristic under compression loadings indicating that the debonding of the fiber from the protective layer is not probable. The produced samples are examined by scanning electron microscopy and X-ray diffraction to assess the physical properties of the tool. Microstructural images reveal no cracks and porosity around the fiber indicating a good bonding between the fiber and the surrounding media. Material characterizations of the manufactured tool are also discussed.