New calibration method to measure rake face temperature of the tool during dry orthogonal cutting using thermography

Soler, D.; Aristimuño, Patxi; Saez-de-Buruaga, M.; Garay, A.; Arrazola, P.J.

doi:10.1016/j.applthermaleng.2018.03.056

Cited by 26 publications

(14 citation statements)

References 28 publications

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“…Therefore, thermal losses could play a relevant role and the temperature inside the workpiece (plane strain) could be notably higher than the one measured. This was stated, for instance, by [24], observing a gap higher than 100 • C between the visible face and the center of the tool.…”

Section: Model Validationmentioning

confidence: 91%

“…That is why, nowadays, infrared techniques are gaining relevance [23] once sources of error such as emissivity, reflections, absorption and obstructions have been controlled. For instance, they have been successfully used to measure tool temperature fields during orthogonal dry cutting by different authors [24,25]. The tool-chip interface temperature was also measured by Heigel et al [26] during machining of Ti6Al4V.…”

Section: Ref Materials Flow Stress Law Ductile Failure Law Friction Lawmentioning

confidence: 99%

“…The tool-chip interface temperature was also measured by Heigel et al [26] during machining of Ti6Al4V. The main advantages of using the infrared technique lie in the fact that it is fast and a non-intrusive method, therefore allowing thermal fields to be measured [24,27]. Franchi et al [18] measured workpiece temperature through the infrared technique.…”

Section: Ref Materials Flow Stress Law Ductile Failure Law Friction Lawmentioning

confidence: 99%

See 2 more Smart Citations

Inverse Identification of the Ductile Failure Law for Ti6Al4V Based on Orthogonal Cutting Experimental Outcomes

Sela

Soler

Ortiz-de-Zarate

et al. 2021

Metals

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Despite the prevalence of machining, tools and cutting conditions are often chosen based on empirical databases, which are hard to be made, and they are only valid in the range of conditions tested to develop it. Predictive numerical models have thus emerged as a promising approach. To function correctly, they require accurate data related to appropriate material properties (e.g., constitutive models, ductile failure law). Nevertheless, material characterization is usually carried out through thermomechanical tests, under conditions far different from those encountered in machining. In addition, segmented chips observed when cutting titanium alloys make it a challenge to develop an accurate model. At low cutting speeds, chip segmentation is assumed to be due to lack of ductility of the material. In this work, orthogonal cutting tests of Ti6Al4V alloy were carried out, varying the uncut chip thickness from 0.2 to 0.4 mm and the cutting speed from 2.5 to 7.5 m/min. The temperature in the shear zone was measured through infrared measurements with high resolution. It was observed experimentally, and in the FEM, that chip segmentation causes oscillations in the workpiece temperature, chip thickness and cutting forces. Moreover, workpiece temperature and cutting force signals were observed to be in counterphase, which was predicted by the ductile failure model. Oscillation frequency was employed in order to improve the ductile failure law by using inverse simulation, reducing the prediction error of segmentation frequency from more than 100% to an average error lower than 10%.

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Section: Model Validationmentioning

confidence: 91%

Section: Ref Materials Flow Stress Law Ductile Failure Law Friction Lawmentioning

confidence: 99%

Section: Ref Materials Flow Stress Law Ductile Failure Law Friction Lawmentioning

confidence: 99%

See 1 more Smart Citation

Inverse Identification of the Ductile Failure Law for Ti6Al4V Based on Orthogonal Cutting Experimental Outcomes

Sela

Soler

Ortiz-de-Zarate

et al. 2021

Metals

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show abstract

“…Interaction of the cutting tool with the workpiece imposes enormous deformation work in a small volume in a very short time, which complicates the study of the thermomechanical processes at the cutting edge by conventional means. Up till now this challenge has been addressed by post-machining structural analysis of the tool, workpiece 1 and the chip 2 , different theoretical approaches summarized in 3 – 5 , or fast rate in-operando optical analysis utilizing high speed cameras 6 – 9 .…”

Section: Introductionmentioning

confidence: 99%

In-SEM micro-machining reveals the origins of the size effect in the cutting energy

Medina-Clavijo

Ortiz-de-Zarate

Sela

et al. 2021

Sci Rep

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High-precision metal cutting is increasingly relevant in advanced applications. Such precision normally requires a cutting feed in the micron or even sub-micron dimension scale, which raises questions about applicability of concepts developed in industrial scale machining. To address this challenge, we have developed a device to perform linear cutting with force measurement in the vacuum chamber of an electron microscope, which has been utilised to study the cutting process down to 200 nm of the feed and the tool tip radius. The machining experiments carried out in-operando in SEM have shown that the main classical deformation zones of metal cutting: primary, secondary and tertiary shear zones—were preserved even at sub-micron feeds. In-operando observations and subsequent structural analysis in FIB/SEM revealed a number of microstructural peculiarities, such as: a substantial increase of the cutting force related to the development of the primary shear zone; dependence of the ternary shear zone thickness on the underlaying grain crystal orientation. Measurement of the cutting forces at deep submicron feeds and cutting tool apex radii has been exploited to discriminate different sources for the size effect on the cutting energy (dependence of the energy on the feed and tool radius). It was observed that typical industrial values of feed and tool radius imposes a size effect determined primarily by geometrical factors, while in a sub-micrometre feed range the contribution of the strain hardening in the primary share zone becomes relevant.

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“…Temperature is a very important physical quantity. For temperature measurement, many techniques are available, e.g., thermocouple [1,2], thermistor [3], resistance temperature detector [4], and infrared thermography [5][6][7][8], etc. As an advanced measurement technology, infrared thermography can transform the thermal energy emitted by objects into an electronic video signal [9][10][11][12].…”

Section: Introductionmentioning

confidence: 99%

Application of silicon-based camera for measurement of non-homogeneous thermal field on realistic specimen surface

Zhang

Marty

Maynadier

et al. 2019

Applied Thermal Engineering

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The high-cost low-resolution infrared cameras operating in middle infrared spectral ranges are widely used to detect the thermal fields. In this study, a low-cost high-resolution silicon-based sensor camera operating in near infrared spectral ranges is used to perform the observation of the thermal fields on the realistic specimen surface. In near-infrared spectral ranges, a small temperature variation led to a large modification in the sensor illumination, inducing acquired images with over saturation or poor dynamic range of gray levels. To address this problem, an algorithm was used to precisely adjust the exposure time to acquire images with constant gray level whatever the temperature evolution is, and then used in heating experiment of a steel specimen. Results showed that images with constant gray level could be acquired during the experiment. A special radiometric model was used to perform near-infrared thermography. Based on this radiometric model, the thermal fields on steel specimen surface were successfully reconstructed without measuring surface emissivity.

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New calibration method to measure rake face temperature of the tool during dry orthogonal cutting using thermography

Cited by 26 publications

References 28 publications

Inverse Identification of the Ductile Failure Law for Ti6Al4V Based on Orthogonal Cutting Experimental Outcomes

Inverse Identification of the Ductile Failure Law for Ti6Al4V Based on Orthogonal Cutting Experimental Outcomes

In-SEM micro-machining reveals the origins of the size effect in the cutting energy

Application of silicon-based camera for measurement of non-homogeneous thermal field on realistic specimen surface

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