Modelling of tool/chip interface temperature distribution in metal cutting

1994 ◽  
Vol 36 (10) ◽  
pp. 931-943 ◽  
Author(s):  
Hong T. Young ◽  
Tsu L. Chou
Keyword(s):  
Temperature Distribution ◽  
Metal Cutting ◽  
Interface Temperature

A Remote Sensor Method for Determining Average Tool-Chip Interface Temperatures in Metal Cutting

1967 ◽  
Vol 89 (2) ◽  
pp. 333-338 ◽  
Author(s):  
M. P. Lipman ◽  
B. E. Nevis ◽  
G. E. Kane
Keyword(s):  
Mathematical Model ◽  
Temperature Distribution ◽  
Heat Flow ◽  
Metal Cutting ◽  
Accurate Method ◽  
Interface Temperature ◽  
Physical Constants ◽  
Surrounding Environment ◽  
Remote Sensor ◽  
Sensor Technique

This paper shows the development of a mathematical model for determining the average interface temperatures when using a remote sensor. The accuracy of the remote sensor technique was greatly improved by introducing an insulator between the tool and tool-holder. The presence of the insulator provided boundary conditions which enabled a numerical solution to the set of equations representing heat flow and temperature distribution. The model was compared experimentally with a tool-chip thermocouple, and agreement of the order of ± 6 percent was observed. The model can be used not only to determine the average tool-chip interface temperature, but the temperature distribution of the overall tool. The developed model proved to be somewhat insensitive to physical constants and the surrounding environment. Its use as a practical, accurate method for determining cutting temperatures is possible without the need for calibrating tool-chip thermocouples, complicated experimental setups, tedious iterative calculations, over-generalized assumptions, and unavailable physical constants for tools and work materials.

Influence of the Process Variables on the Temperature Distribution in AISI 1045 Turning

2012 ◽  
Vol 557-559 ◽  
pp. 1364-1368
Author(s):  
Yong Feng ◽  
Mu Lan Wang ◽  
Bao Sheng Wang ◽  
Jun Ming Hou
Keyword(s):  
Temperature Distribution ◽  
High Speed ◽  
Metal Cutting ◽  
Constitutive Relations ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Fe Model ◽  
Process Variables ◽  
Machined Surface ◽  
Aisi 1045

High-speed metal cutting processes can cause extremely rapid heating of the work material. Temperature on the machined surface is critical for surface integrity and the performance of a precision component. However, the temperature of a machined surface is challenging for in-situ measurement.So, the finite element(FE) method used to analyze the unique nonlinear problems during cutting process. In terms of heat-force coupled problem, the thermo-plastic FE model was proposed to predict the cutting temperature distribution using separated iterative method. Several key techniques such as material constitutive relations, tool-chip interface friction and separation and damage fracture criterion were modeled. Based on the updated Lagrange and arbitrary Lagrangian-Eulerian (ALE) method, the temperature field in high speed orthogonal cutting of carbon steel AISI-1045 were simulated. The simulated results showed good agreement with the experimental results, which validated the precision of the process simulation method. Meanwhile, the influence of the process variables such as cutting speed, cutting depth, etc. on the temperature distribution was investigated.

Influence of Tool Holder Material on Interfacial, Insert and Tool Holder Temperatures During Turning Operation of Gray Iron

2012 ◽  
Author(s):  
Almir K. Kaminise ◽  
Gilmar Guimaraes ◽  
Marcio B. Da Silva
Keyword(s):  
Temperature Distribution ◽  
Carbon Steel ◽  
Cutting Tool ◽  
Gray Iron ◽  
Cutting Fluid ◽  
Interface Temperature ◽  
Turning Operation ◽  
Tool Holder ◽  
Cutting Insert ◽  
Thermocouple Method

Usually studies related to machining temperature consider a system comprised of workpiece, chip and cutting tool, the effect of tool holder material is not taken in account. However, due to its physical properties, the tool holder material, usually carbon steel, has effect in the dissipation of the heat generated. This work studies the effect of the tool holder material on the temperature distribution during the turning operation of gray iron using cemented carbide cutting tool and without cutting fluid. Five tool holders were manufactured from materials with different heat conductivity: carbon steel, stainless steel, titanium, copper and bronze. Temperatures in eight different positions in the tool holder and cutting insert were measured. The average temperature at the chip tool interface was also measured using the tool-work thermocouple method. The results showed that the measured chip tool interface temperature was less affected by the tool holder material, although the temperature distribution at the cutting tool is highly affected.

scholarly journals Cupronickel B10 and YG6 interface friction characteristics tested on a friction device for metal cutting

2019 ◽  
Vol 11 (11) ◽  
pp. 168781401989022
Author(s):  
Chunjian Liu ◽  
Daochun Xu ◽  
Qingqing Li
Keyword(s):  
Friction Coefficient ◽  
Metal Cutting ◽  
Vibration Reduction ◽  
Interface Temperature ◽  
Friction Behavior ◽  
Conduction Model ◽  
Friction Characteristics ◽  
Interface Friction ◽  
Cupronickel B10 ◽  
Solid Liquid

Friction behavior is an important component of the metal-cutting mechanism. A simple and effective friction device that can yield the desired friction characteristics is required. In this article, a friction device with a solid–liquid–gas vibration reduction was proposed to research the interface friction characteristics. The interface friction characteristics of cupronickel B10 and YG6 were obtained through the new friction device, including the friction force, friction temperatures, and friction coefficient. The results show that an experimental solid–liquid–gas vibration reduction is feasible and effective to obtain the interface friction characteristics. The relationship between the friction-interface temperature T2 and the measured-point temperature T1 that was obtained by a heat-conduction model is linear. For cupronickel B10 and YG6, the friction coefficient gradually decreases with an increase in friction speed, and increases initially and then decreases with an increasing load. Based on the effect of friction temperature, friction speed, and load, a friction model for the interface friction characteristics of cupronickel B10 and YG6 was obtained.

A Remote Temperature Sensing Technique for Estimating the Cutting Interface Temperature Distribution

1986 ◽  
Vol 108 (4) ◽  
pp. 252-263 ◽  
Author(s):  
David Wei Yen ◽  
Paul K. Wright
Keyword(s):  
Inverse Problem ◽  
Temperature Distribution ◽  
Measurement Errors ◽  
Three Dimensional ◽  
Cutting Temperature ◽  
Transformation Matrix ◽  
Dimensional Case ◽  
Interface Temperature ◽  
Unknown Boundary ◽  
Ellipsoidal Coordinates

Cutting temperature is a major factor in controlling tool wear rate. Thus, sensing and control of cutting temperature is important in achieving a desired tool performance. This paper is concerned with estimating the cutting interface temperature distribution based on remote temperature measurements. This class of problems of estimating unknown boundary conditions from known interior quantities is called the inverse problem. The inverse problem of a square insert under steady state conditions is considered in this paper. The temperature distribution in a square insert is best described in Ellipsoidal Coordinates. The mapping functional in the one-dimensional case is solved analytically. The mapping functionals in general three-dimensional cases are solved numerically using the semianalytical finite element method. The mapping functional in a three-dimensional case is represented by a transformation matrix which maps one vector representing the cutting interface temperature distribution to another vector representing the remote temperatures. The transformation matrix is then used to solve the inverse problem of estimating the interface temperature distribution with redundant remote measurements. Measurement errors and transformation matrix errors are imposed in simulation studies. The sensitivity of inverse solutions to these errors is discussed.

Evaluation of the Transient Temperature Distribution of End-Face Sliding Friction Pair Using Infrared Thermometry

2014 ◽  
Vol 613 ◽  
pp. 213-218
Author(s):  
Wei Wei ◽  
Jian Wei Yu ◽  
Tao You ◽  
Xiao Fen Yu ◽  
Yong Hong Wang
Keyword(s):  
Temperature Field ◽  
Temperature Distribution ◽  
Measurement System ◽  
Sliding Friction ◽  
Friction Pair ◽  
Dynamic Performance ◽  
Constant Load ◽  
Interface Temperature ◽  
Transient Temperature ◽  
Ir Thermography

A real-time temperature measurement system was designed for end-face sliding friction pairs with an infrared (IR) probe and IR thermography installed on it. The approximate temperature of contact surface was measured by the probe while non-contact surface’s temperature distribution was determined with the IR thermography. Two experiments with constant load but varied rotational speeds were carried out, and a preliminary study was made to analyze the variation of temperature in the friction process. Furthermore, the probe data was used as thermal load to calculate the temperature field by the FEM model and the result was verified using IR images. The experimental results showed that the infrared measurement system can detect and record the interface-temperature variation accurately. The probe data showed a good dynamic performance with the variation of friction coefficient. In addition, the calculated temperature field showed good accordance with the IR thermography data.

Determining the Effect of Process Control Parameters on Tool - Chip Interface Temperature during Hard Turning of AISI D3 Tool Steel in Dry Condition

2015 ◽  
Vol 813-814 ◽  
pp. 293-298 ◽  
Author(s):  
K. Venkatesh ◽  
T. Senthilvelan
Keyword(s):  
Process Control ◽  
Tool Steel ◽  
Hard Turning ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Shop Floor ◽  
Interface Temperature ◽  
Depth Of Cut ◽  
Control Parameters ◽  
D3 Tool Steel

Hard turning is recent upcoming technology through which surface quality of machined components can be enhanced while comparing with the traditional grinding method. Since the absence of metal cutting fluids during this process, numerous harmful effects on shop floor operators and possible negative impacts on environment can be eliminated. Normally some of the vital machinability aspects such as surface integrity of machined parts has been influenced by magnitude of cutting temperature which evolved in metal cutting interface. Therefore in this experimental investigation, the influence of various process control parameters on tool-chip interface temperature was evaluated during hard turning of AISI D3 tool steel in dry condition. The machining trials were conducted as per the L9 Taguchi DOE approach and subsequent experimental data were analysed with the use of Design-Expert® V7 statistical software. This experiment results revealed that feed rate is having predominant influence in determining the magnitude of cutting temperature followed by depth of cut and cutting speed whereas the influence of cutting tool nose radius is insignificant.

Quasi-Steady-State Temperature Distribution in Periodically Contacting Finite Regions

1981 ◽  
Vol 103 (4) ◽  
pp. 739-744 ◽  
Author(s):  
B. Vick ◽  
M. N. O¨zis¸ik
Keyword(s):  
Heat Transfer ◽  
Thermal Conductivity ◽  
Steady State ◽  
Temperature Distribution ◽  
Interface Temperature ◽  
Quasi Steady State ◽  
Exact Analytical Solutions ◽  
One Dimensional ◽  
Steady State Temperature ◽  
Regular Cycle

Heat transfer across two surfaces which make and break contact periodically according to a continuous regular cycle is investigated theoretically and exact analytical solutions are developed for the quasi-steady-state temperature distribution for a two-region, one-dimensional, periodically contacting model. The effects of the Biot number, the thermal conductivity and thermal diffusivity of the materials and the duration of contact and break periods on the interface temperature and the temperature distribution within the solids are illustrated with representative temperature charts.

Estimation of Crater Temperatures Using Infrared Camera

2000 ◽  
Author(s):  
Patrick Kwon
Keyword(s):  
Steady State ◽  
Temperature Distribution ◽  
Heat Conduction Problem ◽  
Infrared Camera ◽  
Video Camera ◽  
Interface Temperature ◽  
Transient Temperature ◽  
Flux Boundary Condition ◽  
Transient Temperature Distribution ◽  
Aisi 1045

Abstract A new technique is developed to estimate the average steady state chip-tool interface temperature during turning. An infrared (IR) video camera attached on the carriage of the lathe measures the transient cooling behavior on the rake surface of an insert after the feed motion is halted. This allows the zero heat flux boundary condition, where the transient Laplace heat conduction problem can be solved numerically to obtain the temporal and spatial temperature distribution. With the experimentally determined transient temperature distribution, the 1-D ellipsoidal model is used to estimate the average steady-state chip-tool interface temperature during machining. The results on turning Gray Cast Iron (GCI) and AISI 1045 steels with various coated and uncoated carbide inserts are presented.

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