Development and verification of a computer model for thermal distortions in hard turning

Sukaylo, V.; Kaldos, A.; Krukovsky, G.; Lierath, F.; Emmer, T.; Pieper, H.-J.; Kundrák, János; Bana, V.

doi:10.1016/j.jmatprotec.2004.04.169

Cited by 17 publications

(8 citation statements)

References 8 publications

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“…The one exception was flood coolant; in this instance, the temperature change was too abrupt to give an acceptable Biot ratio. Several interesting results can be obtained from Table I. MQL heat transfer coefficients were in the range of 200-300 W/m 2 C. Similarly, other researchers have found the heat transfer coefficient for MQL to be in the range of 500-1,000 W/m 2 C (Li and Liang, 2006;Sukaylo et al, 2004). Flood coolant has an order of magnitude higher heat transfer capacity than MQL.…”

Section: Cooling Ability Of Mqlmentioning

confidence: 68%

Evaluation of the convective heat transfer coefficient for minimum quantity lubrication (MQL)

Kurgin

Dasch

Simon

et al. 2012

Industrial Lubrication and Tribology

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Purpose -The purpose of this paper is to evaluate the cooling ability of minimum quantity lubrication (MQL) cutting fluid. Design/methodology/approach -An experimental system is devised to find the heat transfer coefficient of MQL under simulated reaming conditions. Cooling rate of the specimen is measured with an infrared camera. The effect of air pressure and oil volume on cooling rate is tested. Metal cutting tests are performed to evaluate the effect of heat transfer coefficient on workpiece temperature. Findings -Convective heat transfer coefficient for MQL increases with increasing air pressure. Oil volume has an indeterminate effect on the heat transfer coefficient; however, it is a dominant factor for controlling temperature during reaming. Practical implications -The results of the study can provide guidance to optimize the temperature controlling ability of MQL for production. Originality/value -There is limited information available in literature regarding the heat transfer coefficient of metal working fluids, particularly for MQL. In particular, experiments designed to investigate the effect of air pressure and oil volume on the heat transfer coefficient of the mist have not been previously documented. This information may be used to improve the overall cooling ability of MQL mist, thus increasing its effectiveness at controlling tool wear and maintaining part quality. The other major contribution of this work is to separate the role of the cooling and lubrication for controlling temperature while reaming aluminum. Prior to this study, there has been relatively little research performed for the reaming metal cutting operation, and still less for reaming with MQL. The nature of how metal working fluids control temperature is not fully understood, and this work provides insight as to whether cooling or lubrication plays the dominant role for reaming.

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Section: Cooling Ability Of Mqlmentioning

confidence: 68%

Evaluation of the convective heat transfer coefficient for minimum quantity lubrication (MQL)

Kurgin

Dasch

Simon

et al. 2012

Industrial Lubrication and Tribology

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“…The finite-element method (FEM) is well suited for predicting thermomechanical distortions during machining [13], especially in geometrically complex workpieces such as, for example, an aluminium gearbox casting. In this work the behavior of the entire part is studied, rather than focusing solely on the heating at a local scale [14].…”

Section: Introductionmentioning

confidence: 99%

“…Basically, there are two main techniques to measure workpiece temperature: thermocouples [3,10,11,15,[17][18][19][20][21][22] and infrared methods [13,26,27]. Thermocouples are cheap and easy to handle, and by placing them in the workpiece, internal temperatures can be measured.…”

Section: Introductionmentioning

confidence: 99%

Heat-flow determination through inverse identification in drilling of aluminium workpieces with MQL

Segurajauregui

Arrazola

2015

Prod. Eng. Res. Devel.

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One of the current trends in machining is the reduction or elimination of the use of cutting fluids to reduce economic and ecological costs. As a consequence, heating of the workpieces is increased, leading to greater thermal distortion. This distortion can be predicted using the finite-element method (FEM), provided heat input to the workpiece for the machining operation is known. The aim of this research is to determine the quantity and ratio of heat generated in drilling operations and to quantify the heat transferred to the workpiece based on cutting speed and feed rate. Thus, a detailed study of workpiece heating during the drilling process with minimum quantity of lubricant was conducted, and a combination of experimental and numerical data was used to obtain these parameters. The experiments were carried out on aluminium (Al2017) samples. Drilling torque and temperature of the workpiece were measured. The cutting procedure involved drilling a Ø10 9 15 mm blind hole using uncoated cemented carbide tools. Temperature was measured by infrared methods, and cutting torque was obtained using a piezoelectric dynamometer. The FEM model was developed using the general-purpose software ABAQUS/ StandardÓ v6.5 and the inverse simulation technique was used to calculate heat input to the workpiece for each machining condition. As a general conclusion, an increase in cutting speed and feed rate leads to a decrease in heat input and temperature in the workpiece and thus, thermal distortion of the part.

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“…Thus, issues like surface roughness, residual stresses and material microstructure, tool behavior or tool life are often carefully studied [4][5][6][7].…”

Section: Introductionmentioning

confidence: 99%

“…These structural changes mainly depend on the heating and cooling rates as well as the maximum temperature reached in the contact area [1,9]. This aspect affects the physical properties of the workpiece surface and thus the fatigue life of the component [2][3][4][5][6][7]10].…”

Section: Introductionmentioning

confidence: 99%

Finite-element Modeling and Simulation

Arrazola

2011

Machining of Hard Materials

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This chapter deals with the finite-element method (FEM) of hard machining, mainly turning (two-and three-dimensional (3D)). Results about the influence of working conditions and tool geometry (cutting-edge finishing) on tool forces, temperatures, and stresses when machining AISI 52100 steel are presented. In addition, information about residual stresses obtained through 3D FEM analysis is shown. The aim of the chapter is to demonstrate the possibilities of FEM for understanding the chip formation process in hard turning and to show its capabilities in areas like tool insert design and prediction of the surface state of the machined workpiece. First, a brief summary of the state of the art on hard machining is presented. Then FEM capabilities and limitations are shown. After that, results of process simulations will be provided and compared with those obtained in the literature. Finally, overall conclusions are pointed out and future research direction is discussed. IntroductionHard turning has become a relevant manufacturing process in producing finished components that are made of alloyed steels with hardnesses between 50 and 70 HRC [1]. The main aim of employing hard turning is avoiding the grinding operation which in most cases corresponds to the final operation for the workpiece. Comparisons between both processes show that the demanded surface roughness and ISO tolerance standards can be achieved in both processes, but higher flexibility and material removal rates can be obtained in hard turning.

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Development and verification of a computer model for thermal distortions in hard turning

Cited by 17 publications

References 8 publications

Evaluation of the convective heat transfer coefficient for minimum quantity lubrication (MQL)

Evaluation of the convective heat transfer coefficient for minimum quantity lubrication (MQL)

Heat-flow determination through inverse identification in drilling of aluminium workpieces with MQL

Finite-element Modeling and Simulation

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