In-situ measurement of rake face temperatures in orthogonal cutting

Saelzer, Jannis; Berger, Sebastian; Iovkov, Ivan; Zabel, Andreas; Biermann, Dirk

doi:10.1016/j.cirp.2020.04.021

Cited by 28 publications

(12 citation statements)

References 15 publications

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“…During this time, the rake face temperature can already change. Recently, Saelzer et al [29] developed a new method for rake face temperature measurement utilizing a two-color fibre pyrometer in orthogonal cutting by preparing the workpiece with slots. This useful approach bears only a partly interruption of the chip formation while the chip flow remains intact so that the workpiece material directly leaves the contact zone and an immediate measurement on the rake face is possible.…”

Section: General Challenges In Metal Cutting Investigationmentioning

confidence: 99%

A Numerical-Experimental Study on Orthogonal Cutting of AISI 1045 Steel and Ti6Al4V Alloy: SPH and FEM Modeling with Newly Identified Friction Coefficients

Afrasiabi

Saelzer

Berger

et al. 2021

Metals

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Numerical simulation of metal cutting with rigorous experimental validation is a profitable approach that facilitates process optimization and better productivity. In this work, we apply the Smoothed Particle Hydrodynamics (SPH) and Finite Element Method (FEM) to simulate the chip formation process within a thermo-mechanically coupled framework. A series of cutting experiments on two widely-used workpiece materials, i.e., AISI 1045 steel and Ti6Al4V titanium alloy, is conducted for validation purposes. Furthermore, we present a novel technique to measure the rake face temperature without manipulating the chip flow within the experimental framework, which offers a new quality of the experimental validation of thermal loads in orthogonal metal cutting. All material parameters and friction coefficients are identified in-situ, proposing new values for temperature-dependent and velocity-dependent friction coefficients of AISI 1045 and Ti6Al4V under the cutting conditions. Simulation results show that the choice of friction coefficient has a higher impact on SPH forces than FEM. Average errors of force prediction for SPH and FEM were in the range of 33% and 23%, respectively. Except for the rake face temperature of Ti6Al4V, both SPH and FEM provide accurate predictions of thermal loads with 5–20% error.

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Section: General Challenges In Metal Cutting Investigationmentioning

confidence: 99%

A Numerical-Experimental Study on Orthogonal Cutting of AISI 1045 Steel and Ti6Al4V Alloy: SPH and FEM Modeling with Newly Identified Friction Coefficients

Afrasiabi

Saelzer

Berger

et al. 2021

Metals

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“…Shown in Figure 8 are the SPH results employing different thermal models, as well as a comparison of the rake face temperatures. The bar chart in this figure compares the predicted temperatures with the experimentally measured data from [41], which can, in turn, verify the correctness of the proposed thermal model. The red and blue bars are the arithmetic mean temperature of particles located inside the indicated black frames at the rake face, corresponding to 905 K and 744 K, respectively.…”

Section: Temperature Distributionmentioning

confidence: 53%

“…Therefore, it is beneficial to demonstrate the improvements gained by the proposed model via a quantitative comparison. For this purpose, an orthogonal cutting experiment conducted by Saelzer et al [41] is taken into account, where temperature measurements are available. The case study pertains to machining a Ti6Al4V workpiece at a cutting speed of v c = 20 m/min, an uncut chip thickness of t u = 0.1 mm, and a rake angle of γ = 0°.…”

Section: Temperature Distributionmentioning

confidence: 99%

“…The case study pertains to machining a Ti6Al4V workpiece at a cutting speed of v c = 20 m/min, an uncut chip thickness of t u = 0.1 mm, and a rake angle of γ = 0°. The rake face temperature (T RF ) in this setting is about 680 K. Please note that v c = 20 m/min is the lowest speed available in [41], deliberately chosen here to provide more time for thermal conduction in the chip formation zone. As the runtime associated with this relatively low cutting speed is almost 16x longer than the previous test at v c = 318.5 m/min, these SPH simulations are carried out at a lower resolution and terminated after a cut distance of l c = 0.3 mm.…”

Section: Temperature Distributionmentioning

confidence: 99%

“…Distributions and contours of temperature obtained by SPH using the reference and proposed thermal model. An average of the rake face temperature in simulation results (considering the particles inside the black frames) is compared to the experimental measurement provided by [41]. The color bar is limited to 945 K for better visibility.…”

Section: Temperature Distributionmentioning

confidence: 99%

See 2 more Smart Citations

Smoothed Particle Hydrodynamics Simulation of Orthogonal Cutting with Enhanced Thermal Modeling

et al. 2021

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Smoothed Particle Hydrodynamics (SPH) is a mesh-free numerical method that can simulate metal cutting problems efficiently. The thermal modeling of such processes with SPH, nevertheless, is not straightforward. The difficulty is rooted in the computationally demanding procedures regarding convergence properties and boundary treatments, both known as SPH Grand Challenges. This paper, therefore, intends to rectify these issues in SPH cutting models by proposing two improvements: (1) Implementing a higher-order Laplacian formulation to solve the heat equation more accurately. (2) Introducing a more realistic thermal boundary condition using a robust surface detection algorithm. We employ the proposed framework to simulate an orthogonal cutting process and validate the numerical results against the available experimental measurements.

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Finite Element Simulation of Cutting Temperature Distribution in Coated Tools During Turning Processes

Zhang,

Fan,

Zhang

et al. 2024

Lecture Notes of the Institute for Computer Sciences, Social Informatics and Telecommunications Engineering

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In-situ measurement of rake face temperatures in orthogonal cutting

Cited by 28 publications

References 15 publications

A Numerical-Experimental Study on Orthogonal Cutting of AISI 1045 Steel and Ti6Al4V Alloy: SPH and FEM Modeling with Newly Identified Friction Coefficients

A Numerical-Experimental Study on Orthogonal Cutting of AISI 1045 Steel and Ti6Al4V Alloy: SPH and FEM Modeling with Newly Identified Friction Coefficients

Smoothed Particle Hydrodynamics Simulation of Orthogonal Cutting with Enhanced Thermal Modeling

Finite Element Simulation of Cutting Temperature Distribution in Coated Tools During Turning Processes

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