A Remote Sensor Method for Determining Average Tool-Chip Interface Temperatures in Metal Cutting

Abstract

This paper shows the development of a mathematical model for determining the average interface temperatures when using a remote sensor. The accuracy of the remote sensor technique was greatly improved by introducing an insulator between the tool and tool-holder. The presence of the insulator provided boundary conditions which enabled a numerical solution to the set of equations representing heat flow and temperature distribution. The model was compared experimentally with a tool-chip thermocouple, and agreement of the order of ± 6 percent was observed. The model can be used not only to determine the average tool-chip interface temperature, but the temperature distribution of the overall tool. The developed model proved to be somewhat insensitive to physical constants and the surrounding environment. Its use as a practical, accurate method for determining cutting temperatures is possible without the need for calibrating tool-chip thermocouples, complicated experimental setups, tedious iterative calculations, over-generalized assumptions, and unavailable physical constants for tools and work materials.

Cutting temperatures in hard turning chromium hardfacings with PCBN tooling

“…This will provide useful guidance for the experimental work. The other is to reversely calculate the tool-chip temperature from the measured tool-shim temperature using a similar approach as [16,17,19].…”

“…One method of this technique involves positioning the thermocouple at the back of the cutting insert, i.e. at the interface of the insert and its support [16,17]. This method is much easier to operate and avoids the difficulty of producing holes in the tool materials, which is extremely difficult when using ultra-hard tools.…”

“…This method is much easier to operate and avoids the difficulty of producing holes in the tool materials, which is extremely difficult when using ultra-hard tools. The temperature of the real cutting edge can be deduced based on theoretical temperature fields [16][17][18][19], or finite element simulation [15,20]. Another advantage of this method is that the required thermocouples can be built into the tool holder, making the method attractive for routine measurements and process monitoring [21].…”

Influence of CrN coating in wood machining from heat flux estimation in the tool

“…This inverse approach consists in estimating the heat flux from temperature measurements at one or several locations in the tool. The idea of inverse method appeared enough recently in the literature concerning metal machining [18][19][20][21]. A direct model relating the heat flux to the temperature at the sensors locations is also required.…”

Temperature field and crater wear in metal cutting using a quasi-finite element approach

“…Some of the important investigations are by Gottwein (1.925), Schallbroch and Schaumann (19:17), Kuesters (1956), Olberts (HM9), Lipman et at. (1967), Bickel (1963), Lenz (1966), Chao ei al. (1!…”