Analysis of Tool-Chip Interface Temperature with FEM and Empirical Verification

Authors: M. Bagheri, P. Mottaghizadeh

Abstract:

Reliable information about tool temperature distribution is of central importance in metal cutting. In this study, tool-chip interface temperature was determined in cutting of ST37 steel workpiece by applying HSS as the cutting tool in dry turning. Two different approaches were implemented for temperature measuring: an embedded thermocouple (RTD) in to the cutting tool and infrared (IR) camera. Comparisons are made between experimental data and results of MSC.SuperForm and FLUENT software. An investigation of heat generation in cutting tool was performed by varying cutting parameters at the stable cutting tool geometry and results were saved in a computer; then the diagrams of tool temperature vs. various cutting parameters were obtained. The experimental results reveal that the main factors of the increasing cutting temperature are cutting speed (V ), feed rate ( S ) and depth of cut ( h ), respectively. It was also determined that simultaneously change in cutting speed and feed rate has the maximum effect on increasing cutting temperature.

Keywords: Cutting parameters, Finite element modeling, Temperature measurement, Tool-chip interface temperature.

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1330879

References:

[1] Milton C.Shaw, "Metal cutting principles," Oxford University Press, Arizona State University, 1984.
[2] L. Filicie, D. Umbrello "On the finite element codes capability for tool temperature calculation in machining processes," Journal of material processing Technology (2006) 182-190
[3] H A review of the experimental techniques for the measurement of heat and temperature generated in some manufacturting processes and tribology,(2004) 653-682.
[4] Boothroyd G.Fundamental metal machining and machine tools. New York MaGraw-Hill;1981. p.92-102.
[5] Ihsan Korkut, Mehmet Boy, Ismail Karacan, Ulvi Seker "Investigation of chip-back temperature during machining depending on cutting parameters" Journal materials & design.
[6] Larry Barrentine, "Design of experiment," 1999.
[7] Estimation of Two-dimension Tool Wear Based On Finite Element Method".Hrsg: Prof. Dr.lng.Jurgen Fleischer & Prof. Dr.lng. Hartmut Weule. University of Karlsruhe (TH).
[8] D.O Sullivan, M.Cotterell "Temperature measurement in single point turning" Journal of Material processing & Technology (2001)301-308.
[9] A. Fata, M.R. Razfar, "Measurement Tool Temprature by Finite Elements Methods," 15th Annual International Iranian Mechanical Engineering Conference, 2007.