Temperature fields in a chip during high-speed orthogonal cutting—An experimental investigation

Abstract

During the cutting process, the temperature field in the chip is measured by using the principle of pyrometry in the visible spectral range. The mechanical device developed to reproduce orthogonal cutting conditions and to reach very high cutting speed (up to 120 m/s) is used for a range of velocities from 10 to 70 m/s. The presented experimental results concern two materials chosen following the form of chip generated: a low carbon steel (C15) and a low alloyed medium carbon steel (42CrMo4). The performances of the measurement setup are completed by the possibility of recording real time photographs of the chip formation. These records make the analysis of temperature maps easier and allow specific parameters as the contact length at the tool-chip interface or the shear angle to be determined. The non-uniform heating in the chip is emphasized by the presence of a maximal temperature area. The temperature fields measured for a cutting speed around 20 m/s present maximums of 870 1C for 42CrMo4 and 630 1C for C15 located near the tool-chip interface. The effects of cutting velocity on the maximum temperature value in the chip and the location of this heat zone are presented. This maximum increases with the cutting velocity contrary to its location which presents few variations. The experimental results are compared with an analytical approach. r

Numerical and analytical modeling of orthogonal cutting: The link between local variables and global contact characteristics

“…Experimental data obtained by Sutter and Ranc [32] for steels at high cutting speeds are well correlated with the numerical results displayed in Fig. 17a.…”

Insights Into Machining of a β Titanium Biomedical Alloy from Chip Microstructures

“…Therefore, the actual temperature at the interface between the cutting face of the tool and the chip may be substantially higher than those reported. Additionally, infrared thermography temperature measurements are acknowledged to be subject to substantial error [32,33] and temperatures in the cutting zone are far from uniform, being typically characterised by regions of high temperature gradient [34,35]. The microstructural characterisation of the chips gives some insight into the degree of these temperature gradients for machining of the solution treated and aged Ti-25Nb-3Mo-3Zr-2Sn alloy.…”

“…Predictions of the temperature fields in the chip on the basis of heat generation are complex and have been the subject of various analytical and numerical investigations involving modelling of heat conduction, kinematics, geometries and energy aspects of the machining process. Others have attempted to measure temperature both at the cutting interface zone and across the chip, tool and workpiece through the methods including embedded thermocouples, radiation pyrometers and metallographic techniques [34,35]. In general, the highest temperatures are reportedly near the tool-chip interface in the secondary deformation zone.…”

Study of the performances of nano-case treatment cutting tools on carbon steel work material during turning operation

“…Sutter and Ranc [11] measured the temperature during machining of two steels i.e. C15 and 42CrMo4 for a range of cutting speed around 15-65 m/s.…”