Tool Heat Transfer in Orthogonal Metal Cutting

Abstract

This paper analyzes heat flux transfer in the cutting tool in steady state orthogonal cutting. The method involves an iterative procedure to determine temperature distributions in the tool from varying heat flux transfer conditions. The temperature distributions determined from this procedure were compared with those obtained experimentally. A coincidence of the experimental and theoretical temperature distributions implied that the chosen heat flux model was appropriate. The experimental temperature distributions were obtained using a split carbide tip with special thermosensitive paint net. This prevented any split effect on the contact surfaces by films of any size and type. The investigation has provided two main insights. Firstly, it was apparent that the average temperatures determined from temperature models can be at large variance with those determined based on experimental observations. Thus, these models have to consider the effect of heat flux transfer peculiarity in the cutting tool if accurate predictions are desired. Secondly, it pointed to the necessity to account for such factors as heat flux reflection from tip sides, dependence of thermal properties on temperature and rise in temperature of the workpiece if accurate predictions are desired. It is demonstrated how the most accurate representation of heat transfer processes in the cutting tool can be determined through analyses based on accurate and reliable experimental temperature distributions.

A numerical model to determine temperature distribution in orthogonal metal cutting

“…Ostafiev et al [11] investigated the tool temperature field for various heat flux types at the interface. They evaluated the heat transfer conditions using experimental tool temperature measured by using thermo-sensitive paint.…”

“…In the analytical studies, empirical correlations have been developed to calculate the heat generation and the temperature distribution as a function of cutting conditions [2][3][4][5][6][7][8][9][10][11][12][13][14][15]. The energy equation, mainly, was solved under certain simplified assumptions.…”

A simple method for the estimation of laser absorptivity using heat-sensitive paints

“…On application of these paints on the surface of a sample, it is therefore possible to determine if the corresponding melting temperatures were reached or exceeded in it at that location. As per the manufacturer (Omega Engineering, Inc., USA), the paints are accurate to within 1% and have a response time on the order of 1 ms. Temperatureindicating paints have been previously applied in applications referring to metal cutting [5], and gas turbine blades and rocket motors [6,7].…”

Prediction of cutting temperature in carbide cutting tool using finite element method

“…This makes the prediction of the tool's temperature an important undertaking, as it will optimally adjust the various cutting parameters before-hand for an improved machinability. Ostafieu et al [3] examined tool heat transfer in orthogonal metal cutting under steady state. The iterative procedure was used to determine the temperature distributions on the cutting tool.…”