The Effects of Heat Generation on Cutting Tool and Machined Workpiece

Abstract

Metal cutting processes usually cause heat generation at the cutting zone (around the workpiece-tool intersection). The heat generated during these processes may cause different effects on both the workpiece and tool, this in turn may affect the finished product and the general performance of the machined piece. In this study, a review was done on various types of machining conditions available, effects of heat generated on the workpiece and tool, and the approaches adopted to reduce this heat at cutting zones. This study also focuses on the simulation of percentage ratio of heat removal. To handle the simulation, various approaches of heat removal methods were used to get the percentage ratio using the ansys version 19.1 software. It was discovered that heat generation causes two major types of wear on the tool, crater and flank wear, resulting in the reduction of cutting tool life as well as dimensional inaccuracy, surface damage and severe corrosion cases on the workpiece. Various heat reduction methods and coolant application types were as well studied and their merits and demerits were discussed.

On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

“…Special attention has been paid to high strength alloy steels such as AISI 4340 due to its advanced mechanical properties which lead to its use in a large number of industries, including; automotive, construction and structural engineering, power generation, defense applications and weaponry [18,19]. However, the machining of steel alloys can be difficult due to their uniquely high level of strength which is known to quickly damage cutting tools and generate high levels of stress when machining due to the elevated temperatures produced [20]. This requires the materials from which the cutting tools are made should possess excellent physical and mechanical properties including high hot hardness, fracture toughness, and abrasion resistance, the latter because steel alloys are considered relatively abrasive [21].…”

A Comparative Review of Thermocouple and Infrared Radiation Temperature Measurement Methods during the Machining of Metals

“…Ever since Taylor's work, there has been a stimulus to identify methods of measuring the cutting temperatures during machining. The manufacturing industry, especially the machining industry, has shown great interest in knowing and understanding how heat is generated and distributed during cutting processes [21,22]. Abukshim et al [23] stated that the machining of metals is still not completely understood due to the highly non-linear nature of the process and the complex coupling between deformation and temperature fields.…”

Remote Nondestructive Thermal Control of Elastic Abrasive Cutting

“…Multi-objective optimization provides much more information so as to make a justified decision on the selection of optimum elastic abrasive cutting conditions. There are various algorithms for its implementation, which differ in the type and number of target parameters, as well as in the method for determining the optimal solution [45,49]. To determine the optimum elastic abrasive cutting conditions, multi-purpose optimization was implemented as the area where the temperature parameters under study obtain minimum values were determined.…”