Research Progress of Candidate Vibration Measurement Ceramic Materials and Intelligent Cutting Tools

ABSTRACT

Difficult‐to‐machine materials such as nickel‐based superalloys have been widely applied in critical components in aero‐engines due to their excellent high‐temperature properties. However, conventional cemented carbide tools suffer from short tool life and low efficiency when machining these materials, limiting their application. Ceramic tools, with high hardness and wear resistance, have emerged as important candidates for cutting such materials. In recent years, with increasing demands for machining precision, cutting tools are expected not only to perform cutting functions but also to enable real‐time perception of cutting states for intelligent machining. Vibration signals generated during cutting carry rich information about the machining state. Nevertheless, existing sensor integration approaches are limited by the long distance between the sensor and the cutting zone, which causes significant signal attenuation and makes high‐fidelity perception difficult. Current reviews on intelligent cutting tools have mainly focused on the integration of sensors with tool bodies, while reviews on self‐sensing through the tool material itself remain insufficient. To address this gap, this paper proposes a scheme for structurally and functionally integrated ceramic tools that endows the tool with self‐sensing capability from the material perspective. The properties and classifications of vibration‐sensing functional materials, including piezoresistive and piezoelectric materials, are discussed in detail. Existing design approaches for composite cutting tools and strategies for structurally and functionally composite materials are also reviewed. The design mechanisms and performance optimization strategies of various vibration‐sensing materials are systematically elaborated, and the feasibility of the proposed scheme is analyzed.