Analytical and experimental investigations of rake face temperature considering temperature-dependent thermal properties

Weng, Jian; Saelzer, Jannis; Berger, Sebastian; Zhuang, Kejia; Bagherzadeh, Amin; Budak, Erhan; Biermann, Dirk

doi:10.1016/j.jmatprotec.2023.117905

Cited by 30 publications

(4 citation statements)

References 33 publications

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“…Many techniques have been applied to measure the temperature during the metalcutting process. Each technique has its own advantages and limitations depending on the applied measurement conditions [30][31][32][33][34]. In this experiment, cutting temperatures of the contact zone between coated tools and chips were obtained using the IR camera FLIR A315.…”

Section: Methodsmentioning

confidence: 99%

Finite Element Simulation of Orthogonal Cutting of H13-Hardened Steel to Evaluate the Influence of Coatings on Cutting Temperature

Hao,

Tang,

Zhang

et al. 2024

Coatings

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High cutting temperatures increase tool wear and reduce tool life. To achieve a longer tool life, coated carbide tools have been developed. In this study, the influence of tool coatings on the cutting temperature distribution during the orthogonal cutting of H13-hardened steel is investigated. Firstly, four coating materials, including TiC, TiN, Al2O3, and TiAlN, with the same coating thickness, are selected to evaluate the effects of coating materials on cutting temperature with finite element simulation. The maximum temperatures at the tool rake face and the temperatures at the coating–substrate interface are evaluated. It was found that the maximum temperatures at the tool rake face were the lowest and the highest when TiN and Al2O3 coating materials were applied, respectively. The TiAlN coating material had the best thermal barrier property. Then, the temperature distribution along the direction perpendicular to the tool rake face is investigated for TiAlN-coated tools with different coating thicknesses ranging from 3 μm to 10 μm. It is shown that the temperature gradient increases with the coating thickness. The coating thickness should be kept below 5 μm. Finally, cutting experiments validate the availability of the finite element model.

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Section: Methodsmentioning

confidence: 99%

Finite Element Simulation of Orthogonal Cutting of H13-Hardened Steel to Evaluate the Influence of Coatings on Cutting Temperature

Hao,

Tang,

Zhang

et al. 2024

Coatings

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“…The top and right of the workpiece and the bottom and left of the tool (marked in red) were allowed to exchange heat with the environment. During the cutting process, the heat generated in the cutting zone was transferred to the workpiece, tool, chips, and environment [24]. A very high heat transfer coefficient of 10 5 kW/(m 2 K) [25] was selected between the chip, tool, and workpiece so that the temperature field could reach a stable state in a short time.…”

Section: Fe Models Of the Orthogonal Processmentioning

confidence: 99%

Simulation of Work Hardening in Machining Inconel 718 with Multiscale Grain Size

Zhuang

Wang

Zou³

et al. 2023

Materials

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Machining nickel-based alloys always exhibits significant work-hardening behavior, which may help to improve the part quality by building a hardened layer on the surface, while also causing severe tool wear during machining. Hence, modeling the work-hardening phenomenon plays a critical role in the evaluation of tool wear and part quality. This paper aims to propose a numerical model to estimate the work-hardening layer for a deeper understanding of this behavior, employing both recrystallization-based and dislocation-based models to cover workpieces with multiscale grain sizes. Different user routines are implemented in the finite element method to simulate the increase in hardness in the deformed area due to recrystallization or changes in the dislocation density. The validation of the proposed model is performed with both literature and experimental data for Inconel 718 with small or large grain sizes. It is found that the recrystallization-based model is more suitable for predicting the work-hardening behavior of small-grain-size Inconel 718 and the dislocation-based model is better for that of large-grain-size Inconel 718. Further, as an important type of cutting tool in machining Inconel 718, the chamfered tools with different edge geometries are employed in the simulations of machining-induced work hardening. The results illustrate that the uncut chip thickness and chamfer angle have a significant influence on the work-hardening behavior.

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“…To validate their model, they incorporated a thermocouple into the cutting tool during the cutting of a titanium alloy. Weng et al [11] introduced an enhanced analytical thermal model, building upon the Komanduri-Hou framework, to predict the steady-state temperature of the rake face. Their method incorporated temperature-dependent thermal properties and was validated through direct in situ temperature measurements using a two-color pyrometer.…”

Section: Introductionmentioning

confidence: 99%

Transient Temperature at Tool–Chip Interface during Initial Period of Chip Formation in Orthogonal Cutting of Inconel 718

Alammari,

Weng,

Saelzer

et al. 2024

Materials

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Machining nickel-based super alloys such as Inconel 718 generates a high thermal load induced via friction and plastic deformation, causing these alloys to be among most difficult-to-cut materials. Localized heat generation occurring in machining induces high temperature gradients. Experimental techniques for determining cutting tool temperature are challenging due to the small dimensions of the heat source and the chips produced, making it difficult to observe the tool–chip interface. Therefore, theoretical analysis of cutting temperatures is crucial for understanding heat generation and temperature distribution during cutting operations. Periodic heating and cooling occurring during cutting and interruption, respectively, are modeled using a hybrid analytical and finite element (FE) transient thermal model. In addition to identifying a transition distance associated with initial period of chip formation (IPCF) from apparent coefficient of friction results using a sigmoid function, the transition temperature is also identified using the thermal model. The model is validated experimentally by measuring the tool–chip interface temperature using a two-color pyrometer at a specific cutting distance. Due to the cyclic behavior in interrupted cutting, where a steady-state condition may or may not be achieved, transient thermal modeling is required in this case. Input parameters required to identify the heat flux for the transient thermal model are obtained experimentally and the definitions of heat-flux-reducing factors along the cutting path are associated with interruptions and the repeating IPCF. The thermal model consists of two main parts: one is related to identifying the heat flux, and the other part involves the determination of the temperature field within the tool using a partial differential equation (PDE) solved numerically via a 2D finite element method.

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Analytical and experimental investigations of rake face temperature considering temperature-dependent thermal properties

Cited by 30 publications

References 33 publications

Finite Element Simulation of Orthogonal Cutting of H13-Hardened Steel to Evaluate the Influence of Coatings on Cutting Temperature

Finite Element Simulation of Orthogonal Cutting of H13-Hardened Steel to Evaluate the Influence of Coatings on Cutting Temperature

Simulation of Work Hardening in Machining Inconel 718 with Multiscale Grain Size

Transient Temperature at Tool–Chip Interface during Initial Period of Chip Formation in Orthogonal Cutting of Inconel 718

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