An Integrated Telemetric Thermocouple Sensor for Process Monitoring of CFRP Milling Operations

A wireless temperature measurement system was developed and integrated into a cutting tool holder via a thermocouple embedded within the cutting tool. The primary purpose of such an embedded thermal measurement sensor/system is for online process monitoring of machining processes within which thermal damage poses a significant threat both for the environment and productivity alike – as is the case with the machining of carbon fibre reinforced polymer (CFRP) components. A full system calibration was performed on the device. Response times were investigated and thermal errors, in the form of damping and lag, were identified. Experimental temperature results are presented which demonstrate the performance of the integrated wireless telemetry sensor during the edge trimming of CFRP composite materials. Thermocouple positioning relative to heat source effect was among the statistical factors investigated during machining experiments. Initial results into the thermal response of the sensor were obtained and a statistical package was used to determine the presence of significant main effects and interactions between a number of tested factors. The potential application of the embedded wireless temperature measurement sensor for online process monitoring in CFRP machining is demonstrated and recommendations are made for future advancements in such sensor technology.