On the contribution of primary deformation zone-generated chip temperature to heat partition in machining

Fahad, Muhammad; Mativenga, Paul; Sheikh, Mohammad

doi:10.1007/s00170-012-4711-1

Cited by 16 publications

(6 citation statements)

References 30 publications

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“…This is due to the reduction in friction at the cutting tool interface. For this case, the good agreement is also valid for TiN and UCC tools with FE [3,23,29,30].…”

Section: Resultssupporting

confidence: 57%

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Heat partition effect on cutting tool morphology in orthogonal metal cutting using finite element method

Yeşilkaya

Yaman

2019

mech

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It is widely accepted that heat partition and temperature distribution for metal cutting process have a significant effect on the morphological features of the cutting tool. Tool life and cutting accuracy are considerably affected by temperature distribution and heat transfer mechanisms on the tool. When a finite elements model is accurately generated, an understanding of heat partition into the cutting tool without performing experiments can be gained. This study has been completed with the use of uncoated and coated tools in order to predetermine heat partition value entering the cutting tool. In terms of coated tools, tool coating was investigated to assess its effects on heat partition. Finite Element Method was mainly used in combination with the previously generated experimental data in literature. Three-dimensional uncoated and coated models were created and made compatible with finite element modeling software to be able to perform thermal analyses of the cutting process. Finite element transient and steady-state temperature values were calculated and hence the heat intensity value for the cutting tool was determined.

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“…This is due to the reduction in friction at the cutting tool interface. For this case, the good agreement is also valid for TiN and UCC tools with FE [3,23,29,30].…”

Section: Resultssupporting

confidence: 57%

“…In the primary deformation zone, local heat first transfers into the chip and then into the cut-ting tool due to the tool-chip interaction. As a consequence, both primary and secondary deformation zones have influence on the temperature distribution of the tool rake face [23,24].…”

Section: Heat Partitionmentioning

confidence: 99%

Heat partition effect on cutting tool morphology in orthogonal metal cutting using finite element method

Yeşilkaya

Yaman

2019

mech

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“…Therefore, the tertiary deformation zone at tool-workpiece contact can be neglected. 2,3 The fraction of heat enters into the cutting tool, which is stationary relative to the heat source, is based on the determination of heat partition into the cutting tool ( R T ), which defines the percentage of heat going into the tool. The fraction (1− R T ) defines the percentage of heat entering into the moving chip (Figure 1).…”

Section: Introductionmentioning

confidence: 99%

“…Egana et al 42 used a specially designed open tribometer to characterize the macroscopic friction coefficient, heat partition coefficient, and adhesion in the contact versus sliding velocity and contact pressure. Fahad et al 2 used an analytical model to evaluate the chip temperature rise due to the primary deformation zone heat source and estimated its contribution to the cutting tool heat flux to be less than 9.5%. Jiang et al 43 performed an analytical modelling and experimental investigation for the interrupted cutting of steel by the method of inverse heat conduction.…”

Section: Introductionmentioning

confidence: 99%

Thermal modelling of cutting tool temperatures and heat partition in orthogonal machining of high-strength alloy steel

Akbar

Arsalan

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Cutting temperatures and heat partition into the cutting tool are critical factors that significantly affect tool life and part accuracy during metal removal operations, especially in dry machining. Among many thermal modelling studies, uniform heat partition ratio, and/or uniform heat intensity along the tool-chip interface are frequently assumed. This assumption is not valid in actual machining and can lead to erroneous estimated results in the presence of sticking and sliding friction zones. Therefore, it is necessary to accurately predict the cutting tool temperature and heat partition during machining. This paper presents an analytical thermal modelling approach which considers the combined effect of the primary and the secondary heat sources and determines the temperature rise and non-uniform heat partition ratio along the tool-chip interface. Cutting tests were conducted on AISI/SAE 4140 high-strength alloy steel using carbide cutting tools over a wide range of cutting speeds. Cutting temperatures were measured experimentally using an infrared thermal imaging camera. Experimentally established sticking and sliding friction regions were used to evaluate non-uniform frictional heat intensity along the tool-chip interface. The temperature matching condition along the tool-chip interface leads to the solution of distributed non-uniform heat partition ratio by solving a set of linear equations through programming in MATLAB®. Experimental results show to be consistent well with those obtained from the thermal model, yielding a relative difference of predicted average tool-chip interface temperature from −0.8% to 6.3%. It is found that average heat partition into the cutting tool ( RT) varies from 35% down to 15% for the entire range of cutting speeds. These results suggest that, to address the thermal problem in metal cutting, the research and development of tooling should also focus on reducing friction on the tool rake face in addition to the contribution of the combined effect of primary and secondary heat sources on temperature rise at the tool-chip interface.

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“…The tool-chip contact length influences the friction of tool-chip contact interface. Notable investigations on the tool-chip contact length in metal machining have been performed over the last five decades such as those by Friedman [22], Balaji [13,23], Mativenga and Sheikh [15,[24][25][26][27] and Grzesik [14]. Mativenga et al [25] pointed out that cutting tool and workpiece material, cutting parameters and cutting operation type affected tool-chip contact length.…”

Section: Introductionmentioning

confidence: 99%

Influences of TiAlN Coating on Cutting Temperature during Orthogonal Machining H13 Hardened Steel

et al. 2019

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TiAlN has been widely used in cutting tool coating due to its excellent mechanical and thermal performances. However, the research on the TiAlN coating effect on cutting temperature is not comprehensive enough. In this paper, the friction tests at elevated temperature and hard machining H13 hardened steel tests are conducted by using TiAlN coated tools and uncoated tools, respectively. The results of using TiAlN coated tools are compared with those from using uncoated tools. It is found that the coefficient of friction (COF) between TiAlN coated tool and H13 hardened steel is reduced to 0.63 at 800 °C. The COF value is 0.75 for uncoated tool. Under the same cutting conditions, the TiAlN coating shortens tool-chip contact length. The tangential cutting forces and cutting zone temperatures are decreased with smaller COF and shorter tool-chip contact length. Due to the lower thermal conductivities of TiAlN coating and the Al2O3 oxide layer formatted at tool rake face, the cutting heat conducted into cutting tool substrate was reduced. The cutting temperatures in TiAlN coated tool substrate are decreased by at least 10.68% in this study. The TiAlN coating reduces the cutting temperature by decreasing the cutting heat generation and conduction.

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On the contribution of primary deformation zone-generated chip temperature to heat partition in machining

Cited by 16 publications

References 30 publications

Heat partition effect on cutting tool morphology in orthogonal metal cutting using finite element method

Heat partition effect on cutting tool morphology in orthogonal metal cutting using finite element method

Thermal modelling of cutting tool temperatures and heat partition in orthogonal machining of high-strength alloy steel

Influences of TiAlN Coating on Cutting Temperature during Orthogonal Machining H13 Hardened Steel

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