Modeling of Cutting Temperature in Near Dry Machining

2005 ◽  
Vol 128 (2) ◽  
pp. 416-424 ◽  
Author(s):  
Kuan-Ming Li ◽  
Steven Y. Liang
Keyword(s):  
Heat Source ◽  
Heat Loss ◽  
Temperature Rise ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Heat Sources ◽  
Dry Machining ◽  
Machining Processes ◽  
Tool Flank Wear ◽  
Dry Cooling

Near dry machining refers to the condition of applying cutting fluid at relatively low flow rates, on the order of 2-100ml∕h, as opposed to the conventional way of using either a large quantity, typically of about 10l∕min, as in wet machining; or no fluid at all, as in dry machining. One important expectation of applying fluids is to control the cutting temperature, which is an important parameter for tool life and part dimensional accuracy in machining processes. In this context, the understanding of cutting temperature variation corresponding to the near dry cooling and lubrication is of interest. This paper models the temperature distributions in the cutting zone under through-the-tool near dry cooling condition. The heat source method is implemented to estimate the cutting temperatures on the tool-chip interface and the tool-workpiece interface. For the temperature rise in the chip, the effects of the primary heat source and the secondary heat source were modeled as moving heat sources. For the temperature rise in the tool, the effects of the secondary heat source, the heat loss due to cooling, and the rubbing heat source due to the tool flank wear, were modeled as stationary heat sources. For the temperature rise in the workpiece, the primary heat source, the heat loss due to cooling, and the rubbing heat source due to the tool flank wear were modeled as moving heat sources. The model describes the dual effects of air-oil mixture in near dry machining in terms of the reduction of cutting temperature through the cooling effect, as well as the reduction of heat generation through the lubricating effect. To pursue model calibration and validation, embedded thermocouple temperature measurement in cutting medium carbon steels with uncoated carbide insets were carried out. The model predictions and experimental measurements show reasonable agreement and results suggest that the combination of the cooling and the lubricating effects in near dry machining reduces the cutting temperatures on the tool-chip interface by about 8% with respect to dry machining. Moreover, the cutting speed remains a dominant factor in cutting temperature compared with the feed and the depth of cut in near dry machining processes.

Modelling of the cutting temperature distribution under the tool flank wear effect

2003 ◽  
Vol 217 (11) ◽  
pp. 1195-1208 ◽  
Author(s):  
Y Huang ◽  
S Y Liang
Keyword(s):  
Temperature Distribution ◽  
Tool Wear ◽  
Heat Source ◽  
Shear Zone ◽  
Temperature Rise ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Infinite Medium ◽  
Heat Sources ◽  
Moving Band

The understanding of cutting temperature distribution at the presence of tool wear can aid in addressing important metal cutting issues such as part surface integrity, tool life and dimensional tolerance under practical operating conditions. The effect of tool wear on the cutting temperature distribution was first modelled by Chao and Trigger and there have been very few followers since. In Chao's model, the primary heat source was assumed to have no effect on the workpiece temperature rise and the chip temperature rise was treated as a bulk quantity. This paper analytically quantifies the tool wear effect by taking into account the contributions of the primary heat source and considering the distribution of chip temperature rise. On the chip side, the primary shear zone is modelled as a uniform moving oblique band heat source and the secondary shear zone as a non-uniform moving band heat source within a semi-infinite medium. On the tool side, the effects of both the secondary and the rubbing heat sources are modelled as non-uniform static rectangular heat sources within a semi-infinite medium. For the workpiece side, the study models the primary shear zone as a uniform moving oblique band heat source and the rubbing heat source as a non-uniform moving band heat source within a semi-infinite medium. The proposed model is verified based on the published experimental data in the orthogonal cutting of Armco iron. Furthermore, a comparison case is presented on the temperature variation with respect to cutting speed, feed rate and flank wear length.

Predictive Models for Flank Wear in Near Dry Machining

2005 ◽  
Author(s):  
Kuan-Ming Li ◽  
Steven Y. Liang
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Dominant Factor ◽  
Force Model ◽  
Temperature Model ◽  
Dry Machining ◽  
Cutting Force Model ◽  
Wear Model

The objective of this paper is to present a methodology to analytically model the tool flank wear rate in near-dry turning. The resulting models can serve as a basis to minimize time-consuming machining tests in predicting tool life. Analytical models, including cutting force model, cutting temperature model, and tool wear model, are presented. The cutting force model was established based on Oxley’s model with modifications for lubricating and cooling effect due to the air-oil mixture in near-dry machining. The cutting temperature was obtained by considering a moving or stationary heat source in the tool. The tool wear model contained abrasive mechanism, adhesion mechanism, and diffusion mechanism. The important factors related to this model were contact stresses and temperatures that were obtained from the cutting force model and the cutting temperature model. To develop these models, a set of cutting experiments using carbide tools on AISI 1045 steels were performed to calibrate the coefficients in the models and to verify the proposed flank wear mechanisms. The comparisons between the model-predictive flank wear and experimental results showed that the flank wear in near dry machining can be estimated well by the proposed models. It was also found that the cutting velocity was a dominant factor among the cutting conditions.

Study on Tool Life of Surface Textured Tool in Dry Cutting of Ti-6Al-4V Alloys

2012 ◽  
Vol 538-541 ◽  
pp. 1245-1249 ◽  
Author(s):  
Ze Wu ◽  
Jian Xin Deng ◽  
Jun Zhao
Keyword(s):  
Surface Roughness ◽  
Laser Beam ◽  
Tool Life ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Dry Cutting ◽  
Laser Beam Machining ◽  
Tool Flank Wear

Surface textured tools were fabricated by laser beam machining. Dry cutting of Ti-6Al-4V alloys was carried out with these surface textured tools and conventional tools for comparison. The cutting temperature, tool flank wear and surface roughness of processed workpiece were measured. The experimental formulas of tool life based on DOT method were developed. Results show that the surface textured tool can reduce the surface roughness of workpiece, and the tool life of surface textured tool is improved by 15% or so compared with the conventional one.

The study of the temperature field in an infinite slab under line and plane heat source

2015 ◽  
Vol 25 (1) ◽  
pp. 25-32 ◽  
Author(s):  
Wang Qing-Cheng ◽  
Wu Zhao-Chun ◽  
Zhu Xiang-Ping
Keyword(s):  
Temperature Field ◽  
Heat Source ◽  
Temperature Rise ◽  
Temperature Fields ◽  
Manufacturing Processes ◽  
Heat Sources ◽  
Content Type ◽  
Infinite Slab ◽  
Different Types ◽  
Changing Patterns

Purpose – The purpose of this paper is to reveal the characteristics of the temperature field under different types of heat sources, which are significant to the temperature control encountered in practical manufacturing processes. Design/methodology/approach – The temperature fields in an infinite slab under line or plane heat source are calculated numerically by control volume approach and ADI scheme, and the numerical results of the temperature rise have been compared among the different types of the heat sources. Findings – The numerical results show the different changing patterns of temperature fields under line and plane heat source, respectively, and demonstrate that the magnitude of temperature rise depends strongly on the type of the heat sources. The order of temperature rise from high to low is point, line and plane heat source base on the same input heat. Originality/value – The study is original and findings are new, which demonstrate the different changing patterns of temperature fields and the magnitude of temperature rise under line and plane heat source. The numerical solution is significant for the temperature control in practical manufacturing processes.

scholarly journals Optimization of Cutting Parameters in Hard Turning of OHNS Steel

2019 ◽  
Vol 8 (2S3) ◽  
pp. 43-45 ◽  
Keyword(s):  
Hard Turning ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Cutting Fluid ◽  
Dry Machining ◽  
Parameters Analysis ◽  
Predicted Values ◽  
Experimental Values ◽  
Optimization Of Cutting Parameters

Turning of hardened steel is normally carried out with copious supply of cutting fluid to improve the cutting performance. Most of the cutting fluids in regular use are petroleum based emulsions which create several environmental problems. In this context, pure dry machining is a logical alternative as it is free from the problems associated with the cutting fluid. In this study an effort was made to study the effect of flank wear and cutting temperature during hard turning of OHNS steel under dry condition. A detailed analysis was performed using Taguchi technique to find out the effect of above mentioned parameters. Analysis of Variance (ANOVA) was carried out to find out the influence of individual parameters on flank wear and cutting temperature. Confirmation tests were performed to compare the predicted values with the experimental values and it was found that the results matched well with the experimental results

scholarly journals Effects of Tool Wear on Machined Surface Integrity During Milling of Inconel 718

2021 ◽  
Author(s):  
Liang Tan ◽  
Changfeng Yao ◽  
Dinghua Zhang ◽  
Minchao Cui ◽  
Xuehong Shen
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Tool Wear ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Machined Surface ◽  
Tool Flank Wear ◽  
Machined Surface Integrity

Abstract This paper investigates the effects of tool wear on the machined surface integrity characteristics, including the surface roughness, surface topography, residual stress, microhardness and microstructure, during ball-end milling of Inconel 718. Tool wear, tool lifetime, and cutting force are measured. In addition, a two-dimensional finite element-based model is developed to investigate the cutting temperature distribution in the chip–tool–workpiece contact area. Results show that the ball nose end mill achieves tool lifetime of approximately 350 min. The cutting forces increase sharply with a greater tool flank wear width, while the highest cutting temperature has a decreasing tend at a flank wear width of 0.3 mm. Higher tool flank wear width produces larger surface roughness and deteriorative surface topography. A high-amplitude (approximately −700 MPa) and deep layer (approximately 120 mm) of compressive residual stress are induced by a worn tool with 0.3 mm flank wear width. The surface microhardness induced by new tool is larger than that induced by worn tool. Plastic deformation and strain streamlines are observed within 10 mm depth beneath the surface. The results in this paper provide an optimal tool wear criterion which integrates the surface integrity requirements and the tool lifetime for ball-end finish milling of Inconel 718.

Effect of Tool Flank Wear on the Orthogonal Cutting Process

2007 ◽  
Vol 329 ◽  
pp. 705-710 ◽  
Author(s):  
X.L. Zhao ◽  
Yong Tang ◽  
Wen Jun Deng ◽  
F.Y. Zhang
Keyword(s):  
Cutting Forces ◽  
Cutting Tool ◽  
Flank Wear ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Element Model ◽  
Cutting Process ◽  
Temperature Fields ◽  
Tool Flank Wear ◽  
Chip Separation

A coupled thermoelastic-plastic plane-strain finite element model is developed to study orthogonal cutting process with and without flank wear. The cutting process is simulated from the initial to the steady-state of cutting force and cutting temperature, by incrementally advancing the cutting tool forward. Automatic continuous remeshing is employed to achieve chip separation at the tool tip regime. The effect of the degree of the flank wear on the cutting forces and temperature fields is analyzed. With the flank wear increasing, the maximum cutting temperature values on the workpiece and cutting tool increase rapidly and the distribution of temperature changes greatly. The increase of tool flank wear produced slight increase in cutting forces but significant increase in thrust forces.

Temperature in Semi-Infinite and Cylindrical Bodies Subjected to Moving Heat Sources and Surface Cooling

1970 ◽  
Vol 92 (3) ◽  
pp. 456-464 ◽  
Author(s):  
N. R. DesRuisseaux ◽  
R. D. Zerkle
Keyword(s):  
Heat Source ◽  
Cylindrical Body ◽  
Heat Sources ◽  
Surface Cooling ◽  
Machining Processes ◽  
Infinite Body ◽  
Entire Surface ◽  
Convective Cooling ◽  
Temperature Distributions ◽  
Analytical Results

The theory of moving heat sources is applied to two models to determine the effect of convective surface cooling on temperature distributions. The models chosen consist of a translating semi-infinite body and a rotating cylindrical body, each having a band heat source acting on a portion of the surface and convective cooling acting over the entire surface. The analytical results can be utilized to predict temperature distributions occurring in certain machining processes or other processes involving heat sources.

scholarly journals Optimizing Multi-Response Parameters in Turning of AISI1040 Steel Using Desirability Approach

2019 ◽  
Vol 4 (4) ◽  
pp. 905-921
Author(s):  
Srinu Gugulothu ◽  
Vamsi Krishna Pasam
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Tool Flank Wear ◽  
Multi Objective ◽  
Single Objective

In this study, an attempt is made to examine the machining response parameters in turning of AISI 1040 steel under different lubrication environment. Subsequently, design of experiment technique Response surface methodology (RSM) is used for analyzing machining performance by varying cutting conditions with the use of 2wt% of CNT/MoS2(1:2) HNCF. Regression models are developed for multiple machining responses. Optimization is performed for these models by using desirability function, which converts multi-objective into single objective. Then the optimal setting parameters for single objective is found. Significant reduction in main cutting force (Fz), cutting temperature (T), surface roughness(Ra) and tool flank wear (Vb) are found with the use of 2wt% of CNT/MoS2(1:2) HNCF compared to other lubrication environment. Significant factors that affect the main cutting force (Fz), the temperature in the cutting zone are cutting speed, feed rate and depth of cut. Parameter depth of cut has an insignificant effect on tool flank wear and surface roughness (Ra). The optimal cutting conditions for four multi-objective optimization of main cutting force (Fz), cutting temperature, surface roughness (Ra) and tool flank wear are found to be cutting speed 70.25 m/min, feed 0.13 mm/rev and doc 0.5mm at desirability value of 0.907.

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