Heat Conduction Analysis of Coated Cutting Tools with Temperature-Dependent Properties

2009 ◽  
Vol 69-70 ◽  
pp. 389-393 ◽  
Author(s):  
S.J. Zhang ◽  
Zhan Qiang Liu
Keyword(s):  
Heat Conduction ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Temperature Dependent ◽  
Machined Surface ◽  
Average Temperature ◽  
Coated Tools ◽  
Temperature Dependent Properties ◽  
Cutting Processes

The heat generation during metal cutting processes affects accuracy of the machined surface and strongly influences cutting forces and tool wear. Material property of coated tools is one of the most important factors effecting heat conduction and temperature on the rake face of coated tools. To find the action of thermal properties of coated cutting tools on cutting temperature, the temperature distributions were obtained with temperature-dependent properties and temperature-independent properties of coated tools using numerical method. The results indicated that temperature-dependent properties should be considered when calculating cutting temperature. To simplify calculation, selecting the thermal conductivities at average temperature to substitute for temperature-dependent properties can reduce calculating error. The conclusion provides a methodology for analysis of cutting temperature of coated tools, design of cutting tools and analysis of thermal stress within coated tools in manufacturing industries.

scholarly journals An Investigation of the Work Hardening Behavior in Interrupted Cutting Inconel 718 under Cryogenic Conditions

Materials ◽  
2020 ◽  
Vol 13 (9) ◽  
pp. 2202
Author(s):  
Xing Dai ◽  
Kejia Zhuang ◽  
Donglin Pu ◽  
Weiwei Zhang ◽  
Han Ding
Keyword(s):  
Work Hardening ◽  
Inconel 718 ◽  
Metal Cutting ◽  
Surface Deformation ◽  
Cutting Temperature ◽  
Service Performance ◽  
Machined Surface ◽  
Interrupted Cutting ◽  
Cutting Processes ◽  
The Given

The severe work hardening phenomenon generated in the machining of Inconel 718 is harmful to continue cutting processes, while being good for the component’s service performance. This paper investigates the performance of cryogenic assisted machining used in the cutting processes, which can reduce the waste of fluids. The influence of dry and cryogenic machining conditions with different cutting speeds on the work hardening layer is investigated based on the interrupted cutting of Inconel 718. Cutting temperature distribution obtained from simulations under different conditions is used to discuss the potential mechanism of work hardening. Then, the depth of work hardening and degree of work hardening (DWH) are investigated to analyze the surface deformation behavior, which strengthens the machined surface during metal cutting processes. From the cutting experiments, the depth of the work hardening layer can reach more than 60 μm under the given cutting conditions. In addition, a deeper zone can be obtained by the cooling of liquid nitrogen, which may potentially enhance the wear performance of the component. The results obtained from this work can be utilized to effectively control the work hardening layer beneath the surface, which can be applied to improve the service performance.

Sensitivity Analysis for Nonlinear Heat Conduction

2000 ◽  
Vol 123 (1) ◽  
pp. 1-10 ◽  
Author(s):  
Kevin J. Dowding ◽  
Bennie F. Blackwell
Keyword(s):  
Heat Conduction ◽  
General Procedure ◽  
Model Parameters ◽  
Nonlinear Heat Conduction ◽  
Temperature Dependent ◽  
Sensitivity Equations ◽  
Verification Problem ◽  
Temperature Variable ◽  
Numerical Solver ◽  
Temperature Dependent Properties

Parameters in the heat conduction equation are frequently modeled as temperature dependent. Thermal conductivity, volumetric heat capacity, convection coefficients, emissivity, and volumetric source terms are parameters that may depend on temperature. Many applications, such as parameter estimation, optimal experimental design, optimization, and uncertainty analysis, require sensitivity to the parameters describing temperature-dependent properties. A general procedure to compute the sensitivity of the temperature field to model parameters for nonlinear heat conduction is studied. Parameters are modeled as arbitrary functions of temperature. Sensitivity equations are implemented in an unstructured grid, element-based numerical solver. The objectives of this study are to describe the methodology to derive sensitivity equations for the temperature-dependent parameters and present demonstration calculations. In addition to a verification problem, the design of an experiment to estimate temperature variable thermal properties is discussed.

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.

scholarly journals Analysis of critical negative rake angle and friction characteristics in orthogonal cutting of AL1060 and T2

2019 ◽  
Vol 103 (1) ◽  
pp. 003685041987806 ◽  
Author(s):  
Yanchun Ding ◽  
Guangfeng Shi ◽  
Hua Zhang ◽  
Guoquan Shi ◽  
Dongdong Han
Keyword(s):  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Flow Characteristics ◽  
Rake Angle ◽  
Machined Surface ◽  
Friction Characteristics ◽  
Model Based ◽  
Stagnant Region ◽  
Cutting Experiments

The stagnant region often appears in front of the tool cutting edge, which is caused by mechanical inlay and excessive pressing in plastic metal cutting with large negative rake angle tools at a low speed. It results in the change of the effective negative rake angle which can affect the flow characteristics of material, the quality of machined surface and the abrasion loss of cutting tools. However, the critical negative rake angle model based on the existence of the stagnant region has not been reported yet. Therefore, in order to investigate the critical negative rake angle value considering the stagnant region, a critical negative rake angle model based on the principle of minimum required energy is established, and the correctness of the theoretical model is verified by orthogonal cutting experiments. At the same time, the influence of the critical value of the large negative rake angle tool on the machined surface quality is studied through different cutting experiments. These experimental results show that the deviations of both experimental and theoretical critical negative rake angle are less than 5% during the orthogonally cutting of the aluminium (AL1060) and copper (T2) materials by the negative rake angle tool. Meanwhile, the critical negative rake angle is related to the adhesive friction coefficient of tool–workpiece contact surface. The analysis of friction characteristics shows that the deviation values of both theoretical and experimental critical negative rake angle are proportional to the coefficient of adhesive friction and the thickness of the stagnant region. Critical negative rake angle has a significant effect on roughness and residual stress of the machined surface.

scholarly journals Prediction of Surface Roughness When End MillingTi6Al4VAlloy Using Adaptive Neurofuzzy Inference System

2013 ◽  
Vol 2013 ◽  
pp. 1-12
Author(s):  
Salah Al-Zubaidi ◽  
Jaharah A. Ghani ◽  
Che Hassan Che Haron
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
End Milling ◽  
Cutting Tools ◽  
Computing Methods ◽  
Milling Process ◽  
Dry Cutting ◽  
Inference System ◽  
Cutting Processes ◽  
Adaptive Neurofuzzy Inference System

Surface roughness is considered as the quality index of the machine parts. Many diverse techniques have been applied in modelling metal cutting processes. Previous studies have revealed that artificial intelligence techniques are novel soft computing methods which fit the solution of nonlinear and complex problems like metal cutting processes. The present study used adaptive neurofuzzy inference system for the purpose of predicting the surface roughness when end millingTi6Al4Valloy with coated (PVD) and uncoated cutting tools under dry cutting conditions. Real experimental results have been used for training and testing ofANFISmodels, and the best model was selected based on minimum root mean square error. A generalized bell-shaped function has been adopted as a membership function for the modelling process, and its numbers were changed from 2 to 5. The findings provided evidence of the capability ofANFISin modelling surface roughness in end milling process and obtainment of good matching between experimental and predicted results.

Tool Wear Characters in Micro-Milling of Fully Sintered ZrO2 Ceramics by Diamond Coated End Mills

2012 ◽  
Vol 723 ◽  
pp. 365-370 ◽  
Author(s):  
Rong Bian ◽  
Eleonora Ferraris ◽  
Jun Qian ◽  
Dominiek Reynaerts ◽  
Liang Li ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Tools ◽  
Chemical Vapour ◽  
Cutting Parameters ◽  
Micro Milling ◽  
Machined Surface ◽  
Coated Tools ◽  
Machined Surface Quality ◽  
Coating Delamination ◽  
End Mills

This work presents an experimental investigation on micro-milling of fully sintered Zirconia (ZrO2) by diamond coated tools. The experiments were conducted on a Kern MMP 2522 micro-milling centre and WC micro end mills, diamond coated by chemical vapour deposition (CVD) and of stiff geometry were employed as cutting tools. The effects of cutting parameters and milling time on tool wear were investigated. The results revealed that the tool wear characters included diamond coating delamination and wear of substrate WC. Both cutting forces and machined surface quality were affected by tool wear with the progress of milling.

Intelligent Real-Time Predictive Diagnostics for Cutting Tools and Supervisory Control of Machining Operations

1993 ◽  
Vol 115 (3) ◽  
pp. 268-277 ◽  
Author(s):  
K. Ramamurthi ◽  
C. L. Hough
Keyword(s):  
Real Time ◽  
Metal Cutting ◽  
Failure Modes ◽  
Cutting Tools ◽  
Diagnostic System ◽  
Training Time ◽  
Process Diagnosis ◽  
Modes Of Failure ◽  
On Line ◽  
Cutting Processes

Machining economics may be improved by automating the replacement of cutting tools. In-process diagnosis of the cutting tool using multiple sensors is essential for such automation. In this study, an intelligent real-time diagnostic system is developed and applied towards that objective. A generalized Machining Influence Diagram (MID) is formulated for modeling different modes of failure in conventional metal cutting processes. A faster algorithm for this model is developed to solve the diagnostic problem in real-time applications. A formal methodology is outlined to tune the knowledge base during training with a reduction in training time. Finally, the system is implemented on a drilling machine and evaluated on-line. The on-line response is well within the desired response time of actual production lines. The instance and the accuracy of diagnosis are quite promising. In cases where drill wear is not diagnosed in a timely manner, the system predicts wear induced failure and vice versa. By diagnosing at least one of the two failure modes, the system is able to prevent any abrupt failure of the drill during machining.

Effect of Temperature Dependent Properties on the Applicability of the Heat Conduction Equations for Rapid Heat Deposition Applications

2016 ◽  
Author(s):  
John G. Michopoulos ◽  
Andrew Birnbaum ◽  
Athanasios P. Iliopoulos
Keyword(s):  
Differential Equation ◽  
Thermal Properties ◽  
Heat Conduction ◽  
Effect Of Temperature ◽  
Temperature Dependent ◽  
Proper Form ◽  
Heat Deposition ◽  
Hyperbolic Form ◽  
Parabolic Form ◽  
Temperature Dependent Properties

Despite significant efforts examining the suitability of the proper form of the heat transfer partial differential equation (PDE) as a function of the time scale of interest (e.g. seconds, picoseconds, femtoseconds, etc.), very little work has been done to investigate the millisecond-microsecond regime. This paper examines the differences between the parabolic and one of the hyber-bolic forms of the heat conduction PDE that govern the thermal energy conservation on these intermediate timescales. Emphasis is given to the types of problems where relatively fast heat flux deposition is realized. Specifically, the classical parabolic form is contrasted against the lesser known Cattaneo-Vernotte hyperbolic form. A comparative study of the behavior of these forms over various pulsed conditions are applied at the center of a rectangular plate. Further emphasis is given to the variability of the solutions subject to constant or temperature-dependent thermal properties. Additionally, two materials, Al-6061 and refractory Nb1Zr, with widely varying thermal properties, were investigated.

scholarly journals Modelling and prediction of cutting temperature in the machining of H13 hard steel of multi-layer coated cutting tools

2021 ◽  
Author(s):  
Jingjie Zhang ◽  
Zhanqiang Liu ◽  
Chonghai Xu ◽  
Jin Du ◽  
Guosheng Su ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Simulated Data ◽  
Analytical Models ◽  
Interface Temperature ◽  
Transfer Model ◽  
Process Data ◽  
Mono Layer ◽  
Coated Tools

Abstract The coating effect on the cutting temperature has long been a hot topic in understanding heat transfer mechanism in machining coated tools, and especially the multi-layer coated tools. For multi-layer coated tools, the coating structure, coating thickness and coating material will affect the cutting temperature of the tool. This paper is devoted to the cutting temperature in dry turning of H13 hardened steel with multi-layer coatings. New analytical models for estimating coating temperature and coating-substrate interface temperature were proposed. The multi-layer coating can be equivalent to mono-layer composite coating, which applies equivalent coating layer approach, and was developed to estimate the cutting temperature in turning by heat transfer model of mono-layer coated tool. The analyzed results were compared to appropriate experimental process data using thermocouples and FEM simulated data. The models were verified can accurate temperature under the same cutting conditions for two multi-layer coated tools.

scholarly journals Monitoring and neural network modeling of cutting temperature during turning hard steel

2018 ◽  
Vol 22 (6 Part A) ◽  
pp. 2605-2614
Author(s):  
Mirfad Taric ◽  
Pavel Kovac ◽  
Bogdan Nedic ◽  
Dragan Rodic ◽  
Dusan Jesic
Keyword(s):  
Neural Network ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Tool Material ◽  
Cutting Parameters ◽  
Neural Network Modeling ◽  
Machining Parameters ◽  
Average Temperature ◽  
Hard Steel

In this study, cutting tools average temperature was investigated by using thermal imaging camera of FLIR E50-type. The cubic boron nitride inserts with zero and negative rake angles were taken as cutting tools and round bar of EN 90MnCrV8 hardened steel was used as the workpiece. Since the life of the cutting tool material strongly depends upon cutting temperature, it is important to predict heat generation in the tool with intelligent techniques. This paper proposes a method for the identification of cutting parameters using neural network. The model for determining the cutting temperature of hard steel, was trained and tested by using the experimental data. The test results showed that the proposed neural network model can be used successfully for machinability data selection. The effect on the cutting temperature of machining parameters and their interactions in machining were analyzed in detail and presented in this study.

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