Study on the relationship between material removal rate and tool flank temperature in orthogonal turn-milling

Abstract

Tool flank temperature at various intervals after cutting ISO C45 steel through dry turn-milling is measured using a two-color pyrometer with an optical fiber in order to investigate the cutting characteristics. The complicated undeformed chip geometry, which depends on various parameters such as cutting tool diameter, nose radius of cutting tool, number of tooth, workpiece diameter, tool-work revolution speed ratio, depth of cut, feed per tooth, tool axis offset, and cutting distance, is analyzed and visualized by the 3D-CAD system. The effect of cutting parameters associated with material removal rate (MRR) such as workpiece diameter, revolution speed, and feed rate on tool flank temperature is investigated in this study. The analysis by the 3D-CAD system indicated that workpiece diameter affects tool flank temperature, and an increase in 10 mm in diameter results in approximately 40 °C higher temperature at any workpiece revolution speed due to the variation in undeformed chip geometry. The tool flank temperature increases as the feed rate and workpiece revolution speed increase because the cross-sectional cutting area of undeformed chip increases with workpiece revolution speed, and the cutting time during the engagement of each flute also increases with feed rate. Further, almost similar values are obtained between the tool flank temperature and MRR when both the workpiece revolution speed and feed rate are changed.