Estimation of distribution of moving heat source during milling of AISIH13 by inverse heat conduction method

Abstract

This study presents an inverse heat transfer method to estimate the time history of a local heat flow into the work-piece during milling of AISIH13 with considering a 3D thermal model. Temperatures are measured using thermocouples within the work-piece providing input data for the inverse solver. The conjugate gradient method is used as an inverse solver to predict the local time dependent heat flow distribution on the cutting surfaces as well as the temperature distribution in the work-piece. A moving point heat source and a moving plane heat source with different heat source velocity is considered to investigate their influence on the estimated heat flow. Results indicate a good agreement between the experimental and estimated data with an average root mean square error less than 0.2 • C. It can be observed that the heat flow distribution is a function of heat source geometry, cutting speed and feed rate, but the temperature distribution is a weak function of geometry of the moving heat source. Changes of temperature with depth are studied. This study suggests that the developed inverse model can be successfully applied for estimating the heat flow and thermal field in the work-piece during milling.

Temperature during the milling process of aluminum alloys using contact and non-contact methods

“…An adequate position for the five thermocouples to measure the temperature during milling process is used in [13]. They specify that the accuracy of the results depends on the distance between the thermocouples and the active (cutting) surface of the workpiece.…”