{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2025,10,12]],"date-time":"2025-10-12T01:26:11Z","timestamp":1760232371579,"version":"build-2065373602"},"reference-count":37,"publisher":"MDPI AG","issue":"21","license":[{"start":{"date-parts":[[2022,10,26]],"date-time":"2022-10-26T00:00:00Z","timestamp":1666742400000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"name":"VIT University"}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Sensors"],"abstract":"<jats:p>This paper deals with the design and development of a silver\u2013polyester thick film sensor and associated system for the wear-out detection of single-point cutting tools for low-duty cycle machining operations. Conventional means of wear-out detection use dynamometers, accelerometers, microphones, acoustic emission sensors, thermal infrared cameras, and machine vision systems that detect tool wear during the process. Direct measurements with optical instruments are accurate but affect the machining process. In this study, the use of a thick film sensor to detect wear-out for aa real-time low-duty machining operation was proposed to eliminate the limitations of the current methods. The proposed sensor monitors the tool condition accurately as the wear acts directly on the sensor, which makes the system simple and more reliable. The effect of tool temperature on the sensor during the machining operation was also studied to determine the displacement\/deformation of tracing and the polymer substrate at different service temperatures. The proposed tool wear detection system with the silver\u2013polyester thick film sensor mounted directly on the cutting tool tip proved to be highly capable of detecting the tool wear with good reliability.<\/jats:p>","DOI":"10.3390\/s22218200","type":"journal-article","created":{"date-parts":[[2022,10,26]],"date-time":"2022-10-26T07:17:48Z","timestamp":1666768668000},"page":"8200","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":4,"title":["Development of Online Tool Wear-Out Detection System Using Silver\u2013Polyester Thick Film Sensor for Low-Duty Cycle Machining Operations"],"prefix":"10.3390","volume":"22","author":[{"ORCID":"https:\/\/orcid.org\/0000-0002-4144-827X","authenticated-orcid":false,"given":"Jegadeeshwaran","family":"Rakkiyannan","sequence":"first","affiliation":[{"name":"Center for Automation, School of Mechanical Engineering, Vellore Institute of Technology, Chennai 600127, India"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-5814-1728","authenticated-orcid":false,"given":"Lakshmipathi","family":"Jakkamputi","sequence":"additional","affiliation":[{"name":"School of Mechanical Engineering, Vellore Institute of Technology, Chennai 600127, India"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-4866-1428","authenticated-orcid":false,"given":"Mohanraj","family":"Thangamuthu","sequence":"additional","affiliation":[{"name":"Department of Mechanical Engineering, Amrita School of Engineering, Amrita Vishwa Vidyapeetham, Coimbatore 641112, India"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-9130-694X","authenticated-orcid":false,"given":"Abhishek D.","family":"Patange","sequence":"additional","affiliation":[{"name":"Department of Mechanical Engineering, College of Engineering Pune, Pune 411005, India"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-3877-3063","authenticated-orcid":false,"given":"Sakthivel","family":"Gnanasekaran","sequence":"additional","affiliation":[{"name":"Center for Automation, School of Mechanical Engineering, Vellore Institute of Technology, Chennai 600127, India"}]}],"member":"1968","published-online":{"date-parts":[[2022,10,26]]},"reference":[{"key":"ref_1","unstructured":"Seemuang, N. 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