Polycrystalline cubic boron nitride (PCBN) is increasingly being used in manufacturing processes to increase tool life and processing speed. Existing sensors in PCBN tools are unable to provide accurate time- and space-resolved measurements of the thermo-mechanical phenomena at and near the tool-work interface. Using microfabrication techniques along with diffusion bonding, thin film palladium-13wt% chromium (PdCr) alloy micro strain gage sensors were successfully embedded into PCBN structures for potential tooling applications. This article reports on the design, fabrication and characterization of a sensor consisting of three PdCr sensing elements embedded into a PCBN sample. The embedded sensors show good linearity and sensitivity.

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