Product Code: ICAL09_M805

Smart Tools with Embedded Optical Fiber Sensors: Laser Based Layered Manufacturing Procedures
Authors:
Hamidreza Alemohammad, University of Waterloo; Waterloo ON Canada
Ehsan Toyserkani, University of Waterloo; Waterloo ON Canada
Presented at ICALEO 2009

This paper presents a new method for the fabrication of smart cutting tools with embedded optical Fiber Bragg Grating (FBG) sensors. In-situ measurement of loads using smart tools during the machining process improves the productivity and precision and reduces the production time. In this regard, fiber gratings embedded in the macro-scale metallic structures of smart tools can increase the performance and efficiency of the tools. However, since the optical fibers are delicate, and uncontrolled mechanical loads and harsh environmental conditions may damage the fiber and the gratings, the embedding process is challenging. The proposed embedding process consists of two steps: 1) laser microdeposition of thin films, 2) laser solid freeform fabrication for embedding optical fibers. The fabrication of metallic layers on optical fibers is performed using Laser-Assisted Maskless Microdeposition (LAMM). LAMM is an additive and direct-write technique in micro-scale layered manufacturing. To this end, nano-silver thin films are deposited on non-planar surface of optical fiber gratings. After the thin film deposition, the fibers are embedded in the metallic structure of steel and cemented carbide (WC-Co) using laser solid freeform fabrication to realize the concept of smart tools.