To increase machining efficiency, in addition to determining the temperature distribution on the tool surface, it is also necessary to determine the internal temperature distribution. The existing methods for determining the cutting tool temperature distribution and temperature field measurement have significant disadvantages, which limit their applicability and accuracy. The purpose of this study is to develop and test a novel cutting tool temperature field measurement method. The method involves recording the cutting tool thermal expansion fields by laser interferometry and calculating the tool material temperatures with its coefficient of thermal expansion (CTE). Compared with the methods employing infrared thermometry, the method developed in the present study has a higher spatial resolution and a lower achievable field of view due to its usage of light in the visible region. In addition, since the oxidation film has a higher reflection coefficient for visible light, the present method is less sensitive to the thin-film interference on an oxidized tool surface than those using infrared thermometry, eliminating the false shift of the measured temperature. Moreover, by utilizing cheaper optical components and equipment for interference fringe pattern registration, this method is more affordable. Unlike the emissivity coefficient in infrared thermometry, CTE is independent of changes in the surface quality and can be measured with high accuracy by modern dilatometry. Therefore, the developed method, which employs CTE to calculate the temperature, has a higher reliability. In the present study, the efficiency of this method is tested by the orthogonal turning of difficult-to-cut martensitic heat-treated steel with a cemented tungsten carbide tool. Through the experiment, the temperature distributions along the rake face and flank of the tool, as well as the temperature field inside the tool, were obtained. The results can improve the temperature field measurement in machining cutting tools.
The efficiency of a cutting tool can be enhanced through stress–strain and temperature studies. Existing mathematical methods implement simplified boundary conditions, and experimental methods that are either inapplicable to real working conditions or lack the necessary accuracy. This study aims to develop novel experimental methods for stress–strain and temperature field analyses. The approaches entail recording the side deformation fields of the cutting tool by laser interferometry during its operation, separating the deformation fields caused by the cutting forces and heating, as well as calculating the stress–strain and temperature fields using the Young’s modulus, Poisson’s ratio, and coefficient of linear thermal expansion of the tool material. The advantages of these methods include their applicability under real cutting conditions and the possibility to study the stress–strain and temperature fields of a tool during non-stationary operation by high-speed video recording. The study proves the efficiency of the proposed methods by the orthogonal machining of difficult-to-cut steel disc using a cemented carbide tool with positive rake angle. As a result, the temperature and principal stress fields in the tool were determined. Developed methods can help in the study of cutting tool efficiency.
Introduction. The efficiency of the metalworking processes highly depends on the performance of the implemented cutting tools that can be increased by studying its stress-strain state and temperature fields. Existing stress analysis methods either have a low accuracy or are inapplicable for research during the operation of the tools made of materials with high mechanical properties. In addition, the study of temperature fields using known methods is difficult due to the small size of the cutting zone, high temperatures, and a heavy temperature gradient appearing during metal cutting. The purpose of this study is to develop new experimental methods for measuring the stress-strain and temperature fields in the cutting tool during its operation using laser interferometry. The methods include: obtaining interference fringe patterns using an interferometer with the original design, obtaining the tool deformation field during the cutting process by recording the changes in interference fringe patterns using a high-speed camera, processing fringe patterns with the separation of deformations caused by heating and cutting forces, and calculating temperature fields and stress distributions using mechanical properties and the coefficient of thermal expansion of the tool material. The advantages of the developed methods include: applicability under real operating conditions of the cutting tool, ability to study the non-stationary stress-strain state and temperatures during an operation, and achievement of a high spatial resolution and a small field of view for the investigated surface. Results and Discussion. The experimental study confirmed the efficiency of the methods. The results of the study included the fields of stresses and temperatures obtained during the orthogonal cutting of heat-resistant steel with a tool made of cemented tungsten carbide WC-8Co. The developed methods can be used to study the cutting tool efficiency at close to real conditions and in obtaining boundary conditions for the study stress-strain state of a workpiece material near the cutting zone.
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