A new heat transfer analysis in machining based on two steps of 3D finite element modelling and experimental validation

Haddag, Badis; Kagnaya, Tchadja; Nouari, Mohammed; Cutard, Thierry

doi:10.1007/s00231-012-1069-8

Cited by 29 publications

(14 citation statements)

References 42 publications

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“…However, a constant heat transfer coefficient is commonly used to simulate heat transfer across tooling/workpiece interfaces. This does not accurately reflect the heat transfer process in hot stamping simulations, as shown in [3], [11], and [24], where advanced heat transfer models implemented in computer simulations strongly correlate to experimental results.…”

Section: Heat Transfer Calculationmentioning

confidence: 94%

“…The heat transfer coefficient is then obtained from Eqs. (9)- (11). It should be noted that since the heat transfer module depends on the friction routine, it cannot be run independently.…”

Section: Methodsmentioning

confidence: 99%

“…The same is true for constant heat transfer coefficients that are implemented in commercial codes. If advanced heat transfer models are properly implemented, such as in [2], [3], and [11], then there is a stronger correlation between experimental and theoretical results, thus making simulations more reliable for designers and manufacturers. Although Coulomb and Tresca models are suitable for most machine element contacts, but not for metal forming where surfaces stretch, film thicknesses evolve during the process, temperature gradients are severe and real fractional contact areas are very high.…”

Section: Introductionmentioning

confidence: 99%

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Advanced interface models for metal forming simulations

Schmid

Liu

Sanchez-Caballero

et al. 2013

Computational Materials Science

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Friction and heat transfer in metal forming simulations are usually restricted by software to be interface constants, a situation not reflected by the mechanics of real manufacturing processes. A better simulation approach is to use a micromechanics based method to estimate friction and heat transfer as evolutionary phenomenon. This paper presents a friction and heat transfer module for hot forging simulations. The friction model is based on a lubricant film thickness calculation using the Reynolds equation, and a calculation of the fractional contact area based on asperity flattening and roughening. Friction is then portioned between asperity and lubricant contacts. Heat transfer coefficients are calculated using a new model for heat conduction through asperity contact patches and lubricant that takes into account the restriction to heat flow at the contacts. The program is implemented as a user routine in a popular commercially available finite element code, DEFORM 2D.

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Section: Heat Transfer Calculationmentioning

confidence: 94%

“…The heat transfer coefficient is then obtained from Eqs. (9)- (11). It should be noted that since the heat transfer module depends on the friction routine, it cannot be run independently.…”

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Advanced interface models for metal forming simulations

Schmid

Liu

Sanchez-Caballero

et al. 2013

Computational Materials Science

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“…Haddag and Nouari [13] recently developed a multi-steps 3D FE modelling of the turning process to predict the tool wear as well as the heat diffusion in the cutting tool using interface thermomechanical fields. In Haddag et al [14] uniform and non-uniform heat fluxes applied at the tool rake face are assessed to analyse the tool heating. This paper summarizes research works published recently by Haddag et al [15]- [16] about the rough turning of largescale parts.…”

Section: Introductionmentioning

confidence: 99%

Characterization and Modelling of the Rough Turning Process of Large-scale Parts: Tribological Behaviour and Tool Wear Analyses

Haddag¹,

Makich²,

Nouari³

et al. 2015

Procedia CIRP

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International audienceMachining large-scale parts in several industries (nuclear, naval, energy…) is a challenge for machine tools operators. Various problems are encountered, like respecting specified dimensions, deformation of the workpiece during machining, limit of the cutting speed, excessive tool wear, etc. All these difficulties are related to the large size of the machined part, which may have several meters and weigh several hundred kilograms. This study focuses on analysis of the rough turning process of a shell component, having few meters, as a part of steam generators of nuclear power plants. During the rough turning step, a high material removal rate (moderate cutting speed, but high depth-of-cut and feed rate) is necessary to achieve the workpiece in reasonable time. Experimental and theoretical analyses are conducted to highlight the intense thermomechanical loading at the tool–workmaterial interface. Revealed physical phenomena at the tool rake face, like adhesion and abrasive wear types, using various characterization techniques, are reproduced by a numerical model developed to simulate the cutting process. As an interest result, contact discontinuities at the tool–chip interface as well as where the wear is highly localized are well predicted as observed on scanning electron microscope. These contact discontinuities are attributed to the grooved rake face of the insert, designed with a chip breaker to reduce the tool–chip contact area and to promote the chip fragmentation. This study can be helpful for the design of rough turning inserts, by analysing the effectiveness of the rake face geometry (contact area, chip breaker…)

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“…Compared with wet machining, dry cutting shows some superiority such as lower thermal shock and improved useful life of cutting tools, however, the machining friction and the cutting temperature during dry machining are usually greater than those of wet machining. Temperature has an impact on tool wear, thus it is important for the cutting process [5,6]. Aiming at achieving better temperature reduction performance in dry machining process, researchers have proposed a variety of methods and achieved some meaningful results.…”

Section: Introductionmentioning

confidence: 99%

An Independent Internal Cooling System for Promoting Heat Dissipation during Dry Cutting with Numerical and Experimental Verification

et al. 2017

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Abstract:The cooling system has emerged as an effective way to alleviate the excessive heat generation during dry cutting processes. In this paper, we investigated a novel type of internal cooling system, independent of additional mechanical accessories, as a promising cooling alternative. The proposed system is devised as connected internal fluid channels of a-"V" shape created according to the geometric shape of the tool-holder. Enabling quantitative evaluation of the effectiveness of the proposed system, a new numerical approach is established. Within the approach, heat transfer equations are deduced according to thermodynamics; parameters of the equations are specified via analytical modeling. As a result, cutting temperatures can be estimated with high precision according to the outlet temperature. Moreover, a cutting experiment was carried out to verify the effectiveness of the proposed numerical approach. Tool-chip interface temperatures were measured using an infrared thermal imager. Smooth measurements with suppressed noises are derived based on a new adaptive mean filter originated by empirical mode decomposition (EMD). The experimental results demonstrate the proposed system can reduce the temperature substantially (almost 30% at the measuring point) and the results are highly consistent with those of numerical simulation. The proposed cooling system is a prospective enhancement for development of smart cutting tools.

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A new heat transfer analysis in machining based on two steps of 3D finite element modelling and experimental validation

Cited by 29 publications

References 42 publications

Advanced interface models for metal forming simulations

Advanced interface models for metal forming simulations

Characterization and Modelling of the Rough Turning Process of Large-scale Parts: Tribological Behaviour and Tool Wear Analyses

An Independent Internal Cooling System for Promoting Heat Dissipation during Dry Cutting with Numerical and Experimental Verification

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