Fernandes, FilipeMartins, BrunoPatacas, CarlosCavaleiro, AlbanoFaia, Pedro2026-02-022026-02-022025-04-01Bruno Martins, Carlos Patacas, Albano Cavaleiro, Pedro Faia, Filipe Fernandes, Real-time temperature monitoring during titanium alloy machining with cutting tools integrating novel thin-film sensors, Mechanical Systems and Signal Processing, Volume 228, 2025, 112444, ISSN 0888-3270, https://doi.org/10.1016/j.ymssp.2025.1124440888-3270http://hdl.handle.net/10400.22/31769This study explores the integration of titanium aluminum nitride (TiAlN) and zirconium aluminum nitride (ZrAlN) thin-film sensors into cutting tools for real-time temperature monitoring during machining of Ti6Al4V titanium alloy. These sensors, integrated into a multilayer coating for electrical and wear shielding, were deposited directly onto the tool surfaces and calibrated for temperatures up to 750 °C. Due to the integration into the multilayer coating, the sensors exhibit different β sensitivities across the temperature range, ranging from 108 to 825 K for TiAlN and from 950 to 6681 K for ZrAlN. The cutting tests conducted under various cutting conditions, such as cutting speed, feed rate, depth of cut, and cooling, revealed the influence of these parameters on the cutting temperature. Our findings indicate that the sensor position in the tool’s rake face is fundamental for measuring the cutting temperature. The study introduces an innovative tool connector for integration and signal retrieval of the cutting tool in a “plug-and-play” fashion, compatible with industry standards. Additionally, implementing wireless data transmission for real-time and in-situ temperature monitoring offers a pathway for integrating smart cutting tools into modern manufacturing environments, aligning with Industry 4.0.engTool condition monitoring (TCM)Magnetron sputteringSmart toolsTitanium alloysThin-film sensorsresearch article10.1016/j.ymssp.2025.112444