An Analytical Model for Prediction of Tool Temperature Fields during Continuous and Interrupted Cutting

1994 ◽  
Vol 116 (2) ◽  
pp. 135-143 ◽  
Author(s):  
R. Radulescu ◽  
S. G. Kapoor
Keyword(s):  
Analytical Model ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Time History ◽  
Heat Fluxes ◽  
Temperature Fields ◽  
Heat Transfer Analysis ◽  
Interface Temperature ◽  
Tool Temperature ◽  
Interrupted Cutting

An analytical model for prediction of tool temperature fields in metal cutting processes is developed. The model can be applied to any continuous or interrupted three-dimensional cutting process. To accurately represent the heating and cooling cycles encountered during interrupted cutting, the analysis predicts time dependent heat fluxes into the cutting tool. A time history of this heat flux is obtained by performing an energy balance on the chip formation zone. The variation with time of the tool temperature fields is determined from a heat transfer analysis with prescribed heat generation rate. The analysis requires the cutting forces as inputs. The model tool-chip interface temperatures agree well with the experimental tests reported in the literature, for all cutting conditions and work materials investigated. The results indicate that the tool-chip interface temperature increases with cutting speed during both continuous and interrupted cutting.

Effects of Thermal Expansion on Surface Error in Metal Cutting

2000 ◽  
Author(s):  
Chung_sheng Wu ◽  
Chuan-Hsien Kuo ◽  
Wen-Jei Yang
Keyword(s):  
Surface Roughness ◽  
Thermal Expansion ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Surface Profile ◽  
Time History ◽  
Cutting Process ◽  
Machining Process ◽  
Expansion Time ◽  
Cutting Point

Abstract An experimental study is performed to measure thermal expansion and surface roughness of 6061 aluminum workpiece subjected to a cutting process in turning on a lathe. Four capacitance probes are used to detect changes in the air gap between the probes and the surface of the workpiece during the machining process, and after the workpiece is cooled down to the initial temperature. The signal output from the probes is filtered before being fed into a data acquisition system. Operational conditions are varied. The thermal expansion-time history of the workpiece is obtained at different locations behind the cutting point, together with the filtered surface profile of the workpiece. The effects of cutting speed, flank wear length, and workpiece diameter on thermal expansion and average surface roughness are determined. A novel approach is developed to correlate thermal expansion against surface roughness, both in dimensionless form. It is disclosed that these two quantities are linearly related on a semi-logarithmic plot, with all test data falling within upper and lower limits. A quantity analogous to the elastic modulus is defined to characterize the surface roughness of materials resulting from the cutting process in turning. This approach will suggest new directions for the study of surface roughness in machining.

Characterization of Tool–Chip Interface Temperature Measurement With Thermocouple Fabricated Directly on the Rake Face

2019 ◽  
Vol 141 (9) ◽  
Author(s):  
Sinan Kesriklioglu ◽  
Cory Arthur ◽  
Justin D. Morrow ◽  
Frank E. Pfefferkorn
Keyword(s):  
Temperature Measurement ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Smart Manufacturing ◽  
Future Research ◽  
Interface Temperature ◽  
Rake Face ◽  
Serrated Chip ◽  
Cutting Insert

The objective of this work is to fabricate thermocouples directly on the rake face of a commercially available tungsten carbide cutting insert for accurately measuring the tool–chip interface temperature during metal cutting. The thermocouples are sputtered onto the cutting insert using micromachined stencils, are electrically isolated with layers of Al2O3, and receive a top coating of AlTiN for durability. The result is a nonsacrificial thermocouple junction that is approximately 1.3 µm below the rake face of the tool and 30 µm from the cutting edge. Experimental and numerical characterization of the temperature measurement accuracy and response time are presented. The instrumented cutting tool can capture the tool–chip interface temperature transients at frequencies of up to 1 MHz, which enables the observation of serrated chip formation and adiabatic shear events. Temperature measurements from oblique machining of 4140 steel are presented and compared with three-dimensional, transient numerical simulations using finite element analysis, where cutting speed and feed are varied. This method of measuring the tool–chip interface temperature shows promise for future research and smart manufacturing applications.

Identification of Material Constitutive Laws for Machining—Part I: An Analytical Model Describing the Stress, Strain, Strain Rate, and Temperature Fields in the Primary Shear Zone in Orthogonal Metal Cutting

2010 ◽  
Vol 132 (5) ◽  
Author(s):  
Bin Shi ◽  
Helmi Attia ◽  
Nejah Tounsi
Keyword(s):  
Finite Element ◽  
Strain Rate ◽  
Shear Zone ◽  
Analytical Model ◽  
Metal Cutting ◽  
Effective Strain ◽  
Cutting Process ◽  
Temperature Fields ◽  
Stress Strain ◽  
Orthogonal Metal Cutting

To achieve high performance machining, modeling of the cutting process is necessary to predict cutting forces, residual stresses, tool wear, and burr formation. A major difficulty in the modeling of the cutting process is the description of the material constitutive law to reflect the severe plastic deformation encountered in the primary and the secondary deformation zones under high strains, strain rates, and temperatures. A critical literature review shows that the available methods to identify the material constitutive equation for the cutting process may lead to significant errors due to their limitations. To overcome these limitations, a novel methodology is developed in this study. Through conceptual considerations and finite element simulations, the characteristics of the stress, strain, strain rate, and temperature fields in the primary shear zone were established. Using this information and applying the principles of the theory of plasticity, heat transfer, and mechanics of the orthogonal metal cutting, a new distributed primary zone deformation model is developed to describe the distributions of the effective stress, effective strain, effective strain rate, and temperature in the primary shear zone. This analytical model is assessed by comparing its predictions with finite element simulation results under a wide range of cutting conditions using different materials. Experimental validation of this model will be presented in Part II of this study.

Tool Temperature in Titanium Drilling

2007 ◽  
Vol 129 (4) ◽  
pp. 740-749 ◽  
Author(s):  
Rui Li ◽  
Albert J. Shih
Keyword(s):  
Heat Transfer ◽  
Cutting Tools ◽  
Pure Titanium ◽  
Cutting Speed ◽  
Heat Transfer Analysis ◽  
Frictional Heat ◽  
Steady Increase ◽  
Commercially Pure Titanium ◽  
Tool Temperature ◽  
Inverse Heat Transfer

The spatial and temporal distribution of tool temperature in drilling of commercially pure titanium is studied using the inverse heat transfer method. The chisel and cutting edges of a spiral point drill are treated as a series of elementary cutting tools. Using the oblique cutting analysis of the measured thrust force and torque, the forces and frictional heat generation on elementary cutting tools are calculated. Temperatures measured by thermocouples embedded on the drill flank face are used as the input for the inverse heat transfer analysis to calculate the heat partition factor between the drill and chip. The temperature distribution of the drill is solved by the finite element method and validated by experimental measurements with good agreement. For titanium drilling, the drill temperature is high. At 24.4 m/min and 73.2 m/min drill peripheral cutting speed, the peak temperature of the drill reaches 480°C and 1060°C, respectively, after 12.7 mm depth of drilling with 0.025 mm feed per cutting tooth. The steady increase of drill temperature versus drilling time is investigated.

Transient Analysis of Flat Heat Pipes

2003 ◽  
Author(s):  
Unnikrishnan Vadakkan ◽  
Jayathi Y. Murthy ◽  
Suresh V. Garimella
Keyword(s):  
Heat Pipe ◽  
Numerical Procedure ◽  
Simple Algorithm ◽  
Heat Pipes ◽  
Heat Fluxes ◽  
Temperature Fields ◽  
Interface Temperature ◽  
Finite Volume Scheme ◽  
System Pressure ◽  
Energy And Momentum

A stable numerical procedure is developed to analyze the transient performance of flat heat pipes for large input heat fluxes and high wick conductivity. Computation of flow and heat transfer in a heat pipe is complicated by the strong coupling among the velocity, pressure and temperature fields with phase change at the interface between the vapor and wick. A structured collocated finite volume scheme is used in conjunction with the SIMPLE algorithm to solve the continuity, energy and momentum equations. In addition, system pressurization is computed using overall mass balance. The stability of the standard sequential procedure is improved by accounting for the coupling between the evaporator/condenser mass flow rate and the interface temperature and pressure as well as the system pressure. The improved numerical scheme is applied to a flat two-dimensional heat pipe and shown to perform well. Parametric studies are performed by varying the vapor core thickness of the heat pipe and the heat input at the evaporator. The model predictions are validated by comparing the heat pipe wall temperatures against experimental values.

scholarly journals Analytical model of temperature distribution in metal cutting based on Potential Theory

2015 ◽  
Vol 6 (2) ◽  
pp. 89-94 ◽  
Author(s):  
F. Klocke ◽  
M. Brockmann ◽  
S. Gierlings ◽  
D. Veselovac
Keyword(s):  
Potential Theory ◽  
Analytical Model ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Temperature Fields ◽  
Wear Behaviour ◽  
Work Piece ◽  
Machining Processes ◽  
Major Interest ◽  
Cutting Processes

Abstract. Temperature fields evolving during metal cutting processes have also been of major interest. Temperatures in the tool influence the wear behaviour and hence costs, temperatures in the work-piece are directly responsible for later product quality. Due to the high significance of temperatures, many modelling attempts for temperature fields have been conducted, however failed to deliver satisfying results. The present paper describes a novel analytical model using complex functions based on potential theory. Relevant heat sources in metal cutting as well as changing material constants are considered. The model was validated by an orthogonal cutting process and different real machining processes.

Possible examinations of stone machining focused on the relationship between technological parameters and surface quality

2013 ◽  
Vol 4 (1) ◽  
pp. 63-68 ◽  
Author(s):  
Zs. Kun ◽  
I. G. Gyurika
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Theoretical Background ◽  
Motion Path ◽  
Depth Of Cut ◽  
Manufacturing Cost ◽  
Technological Parameters ◽  
The Relationship ◽  
Manufacturing Time

Abstract The stone products with different sizes, geometries and materials — like machine tool's bench, measuring machine's board or sculptures, floor tiles — can be produced automatically while the manufacturing engineer uses objective function similar to metal cutting. This function can minimise the manufacturing time or the manufacturing cost, in other cases it can maximise of the tool's life. To use several functions, manufacturing engineers need an overall theoretical background knowledge, which can give useful information about the choosing of technological parameters (e.g. feed rate, depth of cut, or cutting speed), the choosing of applicable tools or especially the choosing of the optimum motion path. A similarly important customer's requirement is the appropriate surface roughness of the machined (cut, sawn or milled) stone product. This paper's first part is about a five-month-long literature review, which summarizes in short the studies (researches and results) considered the most important by the authors. These works are about the investigation of the surface roughness of stone products in stone machining. In the second part of this paper the authors try to determine research possibilities and trends, which can help to specify the relation between the surface roughness and technological parameters. Most of the suggestions of this paper are about stone milling, which is the least investigated machining method in the world.

Finite Element Simulation of Laser Beam Welding Induced Residual Stresses and Distortions in a T-Joint Configuration for Aeronautic Structures

2009 ◽  
Author(s):  
Muhammad Zain-ul-abdein ◽  
Daniel Ne´lias ◽  
Jean-Franc¸ois Jullien ◽  
Dominique Deloison
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Laser Beam ◽  
Boundary Conditions ◽  
Laser Beam Welding ◽  
Temperature Fields ◽  
Heat Transfer Analysis ◽  
Small Scale ◽  
Joint Configuration ◽  
Simulation Results

Laser beam welding has found its application in the aircraft industry for the fabrication of fuselage panels in a T-joint configuration. However, the inconveniences like distortions and residual stresses are inevitable consequences of welding. The effort is made in this work to experimentally measure and numerically simulate the distortions induced by laser beam welding of a T-joint with industrially used thermal and mechanical boundary conditions on the thin sheets of aluminium 6056-T4. Several small scale experiments were carried out with various instrumentations to establish a database necessary to verify the simulation results. Finite element (FE) simulation is performed with Abaqus and the conical heat source is programmed in FORTRAN. Heat transfer analysis is performed to achieve the required weld pool geometry and temperature fields. Mechanical analysis is then performed with industrial loading and boundary conditions so as to predict the distortion and the residual stress pattern. A good agreement is found amongst the experimental and simulation results.

scholarly journals Search for the Microwave Nonthermal Effect in Microwave Chemistry: Synthesis of the Heptyl Butanoate Ester with Microwave Selective Heating of a Sulfonated Activated Carbon Catalyst

Catalysts ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 466
Author(s):  
Daisuke Sakemi ◽  
Nick Serpone ◽  
Satoshi Horikoshi
Keyword(s):  
Activated Carbon ◽  
Moisture Content ◽  
Homogeneous Medium ◽  
Temperature Fields ◽  
Heat Transfer Analysis ◽  
Conventional Heating ◽  
Microwave Chemistry ◽  
Butanoic Acid ◽  
Selective Heating ◽  
Product Yields

The heptyl butanoate ester was synthesized from butanoic acid and heptanol in a heterogeneous medium in the presence of sulfonated activated carbon (AC-SO3H) catalyst particles subjected to microwave irradiation, which led to higher conversion yields (greater product yields) than conventional heating with an oil bath. The advantage of the microwaves appeared only when the moisture content in the butanoic acid batch(es) was high, suggesting that, unlike conventional heating, the reverse reaction caused by the moisture content and/or by the byproduct water was suppressed by the microwaves. This contrasted with the results that were found when carrying out the reaction in a homogeneous medium in the presence of the 2,4,6-trimethylpyridinium-p-toluene sulfonate (TMP-PTS) catalyst, as product yields were not improved by microwave heating relative to conventional heating. The removal of moisture/water content in the reaction solution was more pronounced when the reactor was cooled, as the reaction yields were enhanced via selective heating of the heterogeneous catalyst. A coupled electromagnetic field/heat transfer analysis gave credence to the selective heating of the AC-SO3H catalyst, which was further enhanced by cooling the reactor. It was deduced that unforeseen impurities and local high-temperature fields generated on the surface of small fine catalyst particles may have had an effect on the microwave chemistry such that the associated phenomena could be mistaken as originating from a nonthermal effect of the microwaves. Accordingly, it is highly recommended that impurities and selective heating be taken into consideration when examining and concluding the occurrence of a microwave nonthermal effect.

A simplified analytical model for radiation dominated ignition of solid fuels exposed to multiple non-steady heat fluxes

2022 ◽  
Vol 237 ◽  
pp. 111866
Author(s):  
Roberto Parot ◽  
José Ignacio Rivera ◽  
Pedro Reszka ◽  
José Luis Torero ◽  
Andrés Fuentes
Keyword(s):  
Analytical Model ◽  
Heat Fluxes ◽  
Solid Fuels ◽  
Steady Heat
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