An analytical study of the effect of crater wear on the response of a remote thermocouple sensor is described. The remote thermocouple sensor is at present being developed as a device for the on-line measurement of tool wear. This technique depends for its operation on the strong influence of wear on the transient temperature variations in the tool. The two-dimensional transient temperature variations in the chip and tool regions are determined using a numerical finite-difference technique. Results are obtained under idealized cutting conditions with a zero wear rate, a normal wear rate, and an accelerated wear rate. Comparisons are made between the three cases to develop relationships for the effect of wear on the temperature at the remote thermocouple location.

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