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.

DISCUSSION. ON HEAT-FLOW AND TEMPERATURE-DISTRIBUTION IN THE GAS-ENGINE.

1909 ◽  
Vol 176 (1909) ◽  
pp. 251-276
Author(s):  
B HOPKINSON ◽  
J C INGLIS ◽  
R E B CROMPTON ◽  
W W BEAUMONT ◽  
E J DAVIS ◽  
...  
Keyword(s):  
Temperature Distribution ◽  
Heat Flow ◽  
Gas Engine

Evaluation of the Rotor Temperature Distribution of an Automotive Turbocharger Under Hot Gas Conditions Including Indirect Experimental Validation

2021 ◽  
Vol 143 (3) ◽  
Author(s):  
Christopher Zeh ◽  
Ole Willers ◽  
Thomas Hagemann ◽  
Hubert Schwarze ◽  
Jörg Seume
Keyword(s):  
Temperature Distribution ◽  
Heat Flow ◽  
Internal Combustion Engines ◽  
Fluid Film ◽  
Experimental Investigations ◽  
Inlet Temperature ◽  
Hot Gas ◽  
Experimental Identification ◽  
Fluid Film Bearings ◽  
Validation Parameters

Abstract While turbocharging is a key technology for improving the performance and efficiency of internal combustion engines, the operating behavior of the turbocharger is highly dependent on the rotor temperature distribution as it directly modifies viscosity and clearances of the fluid film bearings. Since a direct experimental identification of the rotor temperature of an automotive turbocharger is not feasible at an acceptable expense, a combination of numerical analysis and experimental identification is applied to investigate its temperature characteristic and level. On the one hand, a numerical conjugate heat transfer (CHT) model of the automotive turbocharger investigated is developed using a commercial CFD-tool and a bidirectional, thermal coupling of the CFD-model with thermohydrodynamic lubrication simulation codes is implemented. On the other hand, experimental investigations of the numerically modeled turbocharger are conducted on a hot gas turbocharger test rig for selected operating points. Here, rotor speeds range from 64.000 to 168.000 rpm. The turbine inlet temperature is set to 600 °C and the lubricant is supplied at a pressure of 300 kPa with 90 °C to ensure practically relevant boundary conditions. Comparisons of measured and numerically predicted local temperatures of the turbocharger components indicate a good agreement between the analyses. The calorimetrically determined frictional power loss of the bearings as well as the floating ring speed are used as additional validation parameters. Evaluation of heat flow of diabatic simulations indicates a high sensitivity of local temperatures to rotor speed and load. A cooling effect of the fluid film bearings is present. Consequently, results confirm the necessity of the diabatic approach to the heat flow analysis of turbocharger rotors.

CORRESPONDENCE. ON HEAT-FLOW AND TEMPERATURE-DISTRIBUTION IN THE GAS ENGINE.

1909 ◽  
Vol 176 (1909) ◽  
pp. 276-286
Author(s):  
R H FERNALD ◽  
H R RICARDO ◽  
R ROYDS ◽  
C H WINGFIELD ◽  
B HOPKINSON
Keyword(s):  
Temperature Distribution ◽  
Heat Flow ◽  
Gas Engine

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.

Evaluation of the Rotor Temperature Distribution of an Automotive Turbocharger Under Hot Gas Conditions Including Indirect Experimental Validation

2020 ◽  
Author(s):  
Christopher Zeh ◽  
Ole Willers ◽  
Thomas Hagemann ◽  
Hubert Schwarze ◽  
Joerg R. Seume
Keyword(s):  
Temperature Distribution ◽  
Heat Flow ◽  
Internal Combustion Engines ◽  
Fluid Film ◽  
Experimental Investigations ◽  
Inlet Temperature ◽  
Hot Gas ◽  
Experimental Identification ◽  
Fluid Film Bearings ◽  
Validation Parameters

Abstract While turbocharging is a key technology for improving the performance and efficiency of internal combustion engines, the operating behavior of the turbocharger is highly dependent on the rotor temperature distribution as it directly modifies viscosity and clearances of the fluid film bearings. Since a direct experimental identification of the rotor temperature of an automotive turbocharger is not feasible at an acceptable expense, a combination of numerical analysis and experimental identification is applied to investigate its temperature characteristic and level. On the one hand, a numerical conjugate heat transfer (CHT) model of the automotive turbocharger investigated is developed using a commercial CFD-tool and a bidirectional, thermal coupling of the CFD-model with thermohydrodynamic lubrication simulation codes is implemented. On the other hand, experimental investigations of the numerically modelled turbocharger are conducted on a hot gas turbocharger test rig for selected operating points. Here, rotor speeds range from 64.000 to 168.000 rpm. The turbine inlet temperature is set to 600°C and the lubricant is supplied at a pressure of 300 kPa with 90°C to ensure practically relevant boundary conditions. Comparisons of measured and numerically predicted local temperatures of the turbocharger components indicate a good agreement between the analyses. The calorimetrically determined frictional power loss of the bearings as well as the floating ring speed are used as additional validation parameters. Evaluation of heat flow of diabatic simulations indicates a high sensitivity of local temperatures to rotor speed and load. A cooling effect of the fluid film bearings is present. Consequently, results confirm the necessity of the diabatic approach to the heat flow analysis of turbocharger rotors.

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