Prediction of Temperature Distribution in High-Speed End Mill Assisted by Heat Pipe Cooling

2011 ◽  
Vol 311-313 ◽  
pp. 2371-2374
Author(s):  
Hua Wei Ju ◽  
Wei Xiao Tang ◽  
Qing Hua Song ◽  
Hong Liang Zhou
Keyword(s):  
Temperature Distribution ◽  
Heat Pipe ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Dimensional Accuracy ◽  
Machining Process ◽  
Clear Understanding ◽  
End Mill ◽  
Heat Transfer Theory

The cutting temperature is a key factor which directly affects thermal distortion, the machined part’s dimensional accuracy, as well as the tool wear in machining process. Aiming to effectively remove the cutting heat yields in machining process, the cutting tool with heat pipe cooling has been developed in recent years. This research focuses on developing a clear understanding of the temperature distribution in end mill embedded with heat pipe. Mathematical model is developed based on the heat transfer theory and the metal-cutting theory. 3-D finite element models are set up. The thermal boundary conditions are properly set, and contrasts of the temperature field in end mill with and without embedded heat pipes by numerical simulations are given.

Investigation of Heat Pipe Cooling in Drilling Applications: Part 2—Thermal, Structural Static, and Dynamic Analyses

2009 ◽  
Author(s):  
Lin Zhu ◽  
Tien-Chien Jen ◽  
Chen-Long Yin ◽  
Yi-Hsin Yen ◽  
Mei Zhu ◽  
...  
Keyword(s):  
Heat Pipe ◽  
Tool Life ◽  
Cutting Temperature ◽  
Dimensional Accuracy ◽  
Mechanical Effect ◽  
Machining Process ◽  
Drilling Process ◽  
Dynamic Analyses ◽  
Thermal Wear ◽  
3D Finite Element Method

Drilling is a highly complex machining process coupled with thermo-mechanical effect. Both the rapid plastic deformation of the workpiece and the friction along the drill-chip interface can contribute to localized heating and increasing temperature in the workpiece and tool. The cutting temperature at the tool-chip interface plays an important role in determining the tool thermal wear. This in turn affects the dimensional accuracy of the workpiece and the tool life of drill. A new embedded heat pipe technology has been proven to be able to effectively not only remove the heat generated at the tool-chip interface in drilling, but also minimize pollution and contamination of the environment caused by cutting fluids. Less tool wear can then be achieved, thus prolonging the tool life. 3D Finite Element method using COSMOS/works is employed to study coupled effects of thermal, structural static and dynamic analyses in a drilling process to check the feasibility and effectiveness of the heat pipe drill. Four different cases, solid drill without coolant, solid drill with coolant, heat pipe drill, and heat pipe drill with coolant, are explored, respectively. The results from this study can be used to define geometric parameters for optimal designs.

Cutting Force and Friction Modelling in High Speed End-Milling

2015 ◽  
Author(s):  
Sunday J. Ojolo ◽  
Olumuwiya Agunsoye ◽  
Oluwole Adesina ◽  
Gbeminiyi M. Sobamowo
Keyword(s):  
Temperature Field ◽  
Temperature Distribution ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Tool ◽  
End Milling ◽  
Cutting Process ◽  
Machining Process ◽  
Work Piece

Temperature field in metal cutting process is one of the most important phenomena in machining process. Temperature rise in machining directly or indirectly determines other cutting parameters such as tool life, tool wear, thermal deformation, surface quality and mechanics of chip formation. The variation in temperature of a cutting tool in end milling is more complicated than any other machining operation especially in high speed machining. It is therefore very important to investigate the temperature distribution on the cutting tool–work piece interface in end milling operation. The determination of the temperature field is carried out by the analysis of heat transfer in metal cutting zone. Most studies previously carried out on the temperature distribution model analysis were based on analytical model and with the used of conventional machining that is continuous cutting in nature. The limitations discovered in the models and validated experiments include the oversimplified assumptions which affect the accuracy of the models. In metal cutting process, thermo-mechanical coupling is required and to carry out any temperature field determination successfully, there is need to address the issue of various forces acting during cutting and the frictional effect on the tool-work piece interface. Most previous studies on the temperature field either neglected the effect of friction or assumed it to be constant. The friction model at the tool-work interface and tool-chip interface in metal cutting play a vital role in influencing the modelling process and the accuracy of predicted cutting forces, stress, and temperature distribution. In this work, mechanistic model was adopted to establish the cutting forces and also a new coefficient of friction was also established. This can be used to simulate the cutting process in order to enhance the machining quality especially surface finish and monitor the wear of tool.

FEM Analysis of Temperature in High Speed Cutting of TiAl6V4 Alloys

2012 ◽  
Vol 522 ◽  
pp. 201-205
Author(s):  
You Xi Lin ◽  
Cong Ming Yan ◽  
Zheng Ying Lin
Keyword(s):  
Temperature Distribution ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Fem Analysis ◽  
Element Model ◽  
Maximum Temperature ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Radial Depth

mprovements in modeling and simulation of metal cutting processes are required in advanced manufacturing technologies. A three dimensional fully thermal mechanical coupled finite element model had been applied to simulate and analyze the cutting temperature for high speed milling of TiAl6V4 titanium alloy. The temperature distribution induced in the tool and the workpiece was predicted. The effects of the milling speed and radial depth of cut on the maximum cutting temperature in the tool was investigated. The results show that only a rising of temperature in the lamella of the machined surface is influenced by the milling heat. The maximum temperature in the tool increases with increasing radial depth of cut and milling speed which value is 310°C at a speed of 60 m/min and increases to 740°C at 400m/min. The maximum temperature is only effective on a concentrated area at the cutting edge and the location of the maximum temperature moves away from the tool tip for higher radial depths of milling. The predicted temperature distribution during the cutting process is consistent with the experimental results given in the literature. The results obtained from this study provide a fundamental understanding the process mechanics of HSM of TiAl6V4 titanium alloys.

Experiment Study of Oil-Air Lubrication on Cooling of Turning Tools

2011 ◽  
Vol 189-193 ◽  
pp. 3187-3190 ◽  
Author(s):  
Jin Li Wang ◽  
Lin Cai ◽  
Hong Tao Zheng
Keyword(s):  
Metal Cutting ◽  
Research Work ◽  
Cutting Temperature ◽  
Cost Savings ◽  
Machining Process ◽  
Dry Cutting ◽  
Air Lubrication ◽  
Temperature Contrast ◽  
Cooling Technology ◽  
Lubrication Conditions

When lubricants are used according to special requirements, it is possible to achieve considerable cost savings. Compared to conventional coolant cooling technology used in metal cutting, oil-air lubrication increases cooling performance, avoids environmental pollution, reduces running and maintenance costs. The cutting temperature contrast experimental research was based on close to practice 45# steel in dry cutting, wet cutting and oil-air lubrication conditions. The research work concentrated on the superiority of oil-air lubrication cooling and the influence of cutting amount on temperature. The experimental results show that oil-air lubrication is more effective in reducing the cutting temperature than wet cutting or dry cutting, this paper details the cutting temperature curves at several different tests provides a basis for industrial production, improves the level of machining process and the significance was being reported.

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.

Development of Cutting Tools With Micro-Textured Surface for High Speed Machining of Ti-6Al-4V

2021 ◽  
Author(s):  
Mitsuru Hasegawa ◽  
Tatsuya Sugihara
Keyword(s):  
Tool Life ◽  
High Speed ◽  
Metal Cutting ◽  
Failure Process ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Textured Surface ◽  
Textured Surfaces

Abstract In cutting of Ti-6Al-4V alloy, the cutting speed is limited since a high cutting temperature leads to severe tool wear and short tool life, resulting in poor production efficiency. On the other hand, some recent literature has reported that various beneficial effects can be provided by forming micro-textures on the tool surface in the metal cutting process. In this study, in order to achieve high-performance machining of Ti-6Al-4V, we first investigated the mechanism of the tool failure process for a cemented carbide cutting tool in high-speed turning of Ti-6Al-4V. Based on the results, cutting tools with micro textured surfaces were developed under the consideration of a cutting fluid action. A series of experiments showed that the textured rake face successfully decreases the cutting temperature, resulting in a significant suppression of both crater wear and flank wear. In addition, the temperature zone where the texture tool is effective in terms of the tool life in the Ti-6Al-4V cutting was discussed.

Temperature Field Numerical Analysis of Machining Process Based on the Finite Element Analysis

2014 ◽  
Vol 621 ◽  
pp. 611-616 ◽  
Author(s):  
Yan Juan Hu ◽  
Yao Wang ◽  
Zhan Li Wang
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Element Model ◽  
Machining Process ◽  
Element Analysis ◽  
Mechanical Coupling

In order to study the temperature field distribution in the process of machining, the finite element theory was used to establish the orthogonal cutting finite element model, and the key technologies were discussed simultaneously. By using ABAQUS software for cutting AISI1045 steel temperature field of numerical simulation, the conclusion about changing rule of cutting temperature field can be gotten. The results show that this method can efficiently simulate the distribution of temperature field of the workpiece, cutter and scraps, which is effected by thermo-mechanical coupling in metal work process. It provides the theory evidence for the intensive study of metal-cutting principle, optimizing cutting parameters and improving processing technic and so on.

Control of Machining Process for Titanium Alloy Based on Green Cooling and Lubricating Technology

2012 ◽  
Vol 580 ◽  
pp. 7-11
Author(s):  
Yue Zhang ◽  
Li Han ◽  
You Jun Zhang ◽  
Xi Chuan Zhang
Keyword(s):  
Titanium Alloy ◽  
Water Vapor ◽  
High Speed ◽  
Cutting Temperature ◽  
Small Diameter ◽  
Machining Process ◽  
Machined Surface ◽  
Cutting Zone ◽  
Cutting Experiments ◽  
Special Control

The machining process of titanium alloys always need special control by using coolant and lubricant as it is one of the difficult-to-cut materials. The cutting experiments are carried out based on green cooling and lubricating technology. To achieve green cutting of titanium alloy Ti-6Al-4V with water vapor cooling and lubricating, a minitype generator is developed. Compared to dry and wet cutting, the using of water vapor decreases the cutting force and the cutting temperature respectively; enhances the machined surface. And it can help to chip forming and breaking. Water vapor application also improves Ti-6Al-4V machinability. The excellent cooling and lubricating action of water vapor could be summarized that water molecule has polarity, small diameter and high speed, can be easily and rapidly to proceed adsorption in the cutting zone. The results indicate that the using of water vapor has the potential to attain the green cutting of titanium alloy.

Calculating of the Temperature Distribution of Primary Shear Zone in Orthogonal High Speed Cutting Based on the Non-Uniform Volume Moving Heat Source

2009 ◽  
Vol 626-627 ◽  
pp. 105-110 ◽  
Author(s):  
Guo He Li ◽  
Min Jie Wang
Keyword(s):  
Temperature Distribution ◽  
Heat Source ◽  
Shear Zone ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Constitutive Relationship ◽  
Moving Heat Source ◽  
High Speed Cutting ◽  
Strain And Strain Rate

A method was presented for calculating the temperature distribution of primary shear zone in orthogonal high speed cutting based on the non-uniform volume moving heat source. The temperature distribution of primary shear zone in orthogonal high speed cutting was calculated by the dynamic plastic constitutive relationship and the distribution of strain and strain rate of primary shear zone. The results show that the temperature distribution of primary shear zone is uneven, from the original plane to the cutoff plane, the cutting temperature increases continuously. In the middle of primary shear zone, the change of cutting temperature is larger, at the position near to original plant and cutoff plane, the change of cutting temperature is smaller. The cutting temperature increases with the increase of cutting speed and cutting depth, but decreases with the increase of rake angle. The comparison with existing method shows that the method presented in this paper is not only available, but also simple, convenient and more accord with the fact of orthogonal high speed cutting.

Monitoring of End-Mill Process Based on Infrared Imagery with a High Speed Thermography

2014 ◽  
Vol 625 ◽  
pp. 213-218 ◽  
Author(s):  
Masatoshi Shindou ◽  
Hiroyuki Kodama ◽  
Toshiki Hirogaki ◽  
Eiichi Aoyama
Keyword(s):  
High Speed ◽  
High Performance ◽  
Cutting Temperature ◽  
End Mill ◽  
Tool Temperature ◽  
Time Duration ◽  
Rotating Speed ◽  
Tool Position ◽  
The Relationship ◽  
Mill Process

In this study, we perform the end-mill process of a difficult-to-cut material (JIS SUS310 stainless steel) and observe it with high performance infrared thermography. Considering the rotating angle of end-mill tool, a pixel temperature in each frame is investigated to obtain the tool temperature variation after cutting of each tooth in end-mill process. The tool temperature distribution can be analyzed at each rotating tool position in end-mill process from imageries, considering the relationship between the time duration of each frame and the rotating speed of an end-mill tool. Moreover, the tool/holder shape and the number of cutting teeth can be seen to affect the cutting temperature because the tool heat capacity and the heat input are different. The examination and analytical results show this method to be effective to estimate the tool temperature in the end-mill process sufficiently.

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