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

Klocke, Fritz; Brockmann, Matthias; Gierlings, Sascha; Veselovac, D.

doi:10.5194/ms-6-89-2015

Cited by 10 publications

(3 citation statements)

References 8 publications

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“…Therefore, the direct calculation of the entire temperature distribution only works under idealized conditions and assumptions. In addition, many models only resolve the temperature distribution in defined areas of the cutting zone like tool, workpiece or chip [13][14][15] and often require a heat source as input variable. "In summary, there is no general agreement on a partition criterion for the heat transfer into the tool, the chip, and the workpiece, in conventional machining.…”

Section: State Of the Art mentioning

confidence: 99%

Heat Flow into the Tool in Cutting Super Alloy Inconel 718

Augspurger¹,

Peng²,

Klocke³

et al. 2018

JMEA

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Cutting super alloy is a highly sensitive manufacturing process regarding the complex thermo-mechanical interactions in the cutting zone, which finally determine the capability of the process in order to reach economic requirements. The connection between the intensity of heat sources as well as heat partitions into the tool, work piece and chip is yet not fully understood. Thus heat flows and other thermal conditions in the cutting zone cannot be predicted satisfactory, though they influence the chip formation mechanics, the surface integrity, respectively functionality of the machined work piece as well as the tool wear and lifetime. Because of this deficit the ecological and economical design of the manufacturing process is still limited and often not knowledge based. The proposed paper presents a methodology in order to measure and predict heat flows respectively affiliated temperatures during cutting nickel-base super alloy (Inconel 718). The heat flows in the cutting zone are determined by infrared thermography and a further energy balance by post processing the thermal images. A FE-model for chip formation simulation, which is based on CEL (Coupled-Eulerian-Lagrange) formulation, was used to calculate the heat flows. Finally, the results of the simulation and the experiments were compared.

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Section: State Of the Art mentioning

confidence: 99%

Heat Flow into the Tool in Cutting Super Alloy Inconel 718

Augspurger¹,

Peng²,

Klocke³

et al. 2018

JMEA

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“…Therefore, analytical modelling is found more suitable for estimation of responses in the manufacturing of dies and mould manufacturing as these components are manufactured in small size production. In the analytical modelling technique, complex differential equations are required to be solved with the help of various approaches like Green's function (20) (23) (24) (28) (29), moving heat source method (27) Finite difference method (30), Kommanduri and Huang-Liang (31), finite element method (32) and theories like Oxley's theory (33) and inverse heat conduction theory (30) provided by researchers in the recent past. The Separation of variable method has also been used by most researchers for solving non Fourier heat transfer problem (34) (35).…”

Section: Introductionmentioning

confidence: 99%

Empirical modelling for work piece temperature during end milling of inconel 625 using a green’s function approach based on dirac delta function

Kumar¹,

CHANDNA²,

Bhushan³

2021

Journal of Thermal Engineering

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Milling is a very versatile process for the manufacturing of dies and aerospace components. Especially in the manufacturing of thin walled components, the dimensional accuracy is greatly affected due to heat generation and deflection in the wall. Therefore, minimization of heat generation during milling by optimizing controllable input process parameters, leads to improved accuracy in thin walls. In the present study, an empirical model for work piece temperature by solving the non-homogeneous partial differential equation using Green's function has been simplified with Dirac delta approach during the end milling of Inconel625 work-piece with the assumption of single-pass cutting and one-point observation. This technique is normally used for solving the complex higher-order partial differential equation, but it is rarely applied in the heat dissipation problem during manufacturing in the recent past. The empirical approach is more effective and accurate as compared to experimental approaches used earlier in the recent past. To verify the adequacy of the empirical model of work piece temperature, 9 conformational experiments have been performed at 3 different cutting speeds with a constant depth of cut 5 mm and feed per tooth 0.05 mm. A good compromise has been observed among the responses obtained among the results obtained from an empirical approach and experimental observations at different cutting speeds. However, by little modification and adding a small algorithm, this single pass problem can be implemented on the multi-pass problems and even can also be applied to complex shapes.

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“…Sun et al (2017) discussed heat generation during milling of the Ti6Al4V alloy and highlighted on developing a mathematical model for the heat generated and its validation through experimentally measuring the tool workpiece temperature using a semi-artificial thermocouple. Klocke et al (2015) studied the temperature fields in a machining process. The model used is derived on the basis of potential theory.…”

mentioning

confidence: 99%

Impact of instantaneous curvature on force and heat generation in manufacturing processes – a mathematical modelling

Sreerag

Gokul

Vinaykumar

et al. 2020

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Purpose In any machining process, the surface profile of the workpiece is continuously changing with respect to time and input parameters. In a conventional machining process, input parameters are feed and depth of cut whilst other parameters are considered to be constant throughout the process. Design/methodology/approach The direct and indirect participation of this instantaneous curvature can be used to optimize the strategy of cutting operation in terms of different parameters like heat generation-induced stresses, etc. The concepts of the metric tensor and Riemannian curvature tensor are made use in this study as a representation of curvature itself. The objective of this study is to create a mathematical methodology that can be implemented on a highly flexible machining process to find an optimum cutting strategy for a particular output parameter. Findings The study also includes different case studies for the validation of this newly introduced mathematical methodology. Originality/value The study will also find its position in other mechanical processes like forging and casting where instantaneous curvature affects various mechanical properties.

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

Cited by 10 publications

References 8 publications

Heat Flow into the Tool in Cutting Super Alloy Inconel 718

Heat Flow into the Tool in Cutting Super Alloy Inconel 718

Empirical modelling for work piece temperature during end milling of inconel 625 using a green’s function approach based on dirac delta function

Impact of instantaneous curvature on force and heat generation in manufacturing processes – a mathematical modelling

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