Tool–chip thermal conductance coefficient and heat flux in machining: Theory, model and experiment

Kryzhanivskyy, V.; Saoubi, Rachid M.; Ståhl, Jan Eric; Bushlya, Volodymyr

doi:10.1016/j.ijmachtools.2019.103468

Cited by 17 publications

(2 citation statements)

References 32 publications

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“…However, there are a few applications where solids come into contact with each other at much higher pressures, such as at the interface between the tool cutting edge and the workpiece during machining, where the contact pressures can reach several hundred MPa. For this purpose, there are numerical studies [13,14] that show that the contact heat transfer reaches very high values of 100.000 or even 1.000.000 W/m²K, which is 1 or 2 orders of magnitude higher than the values experimentally studied so far. However, only individual operating points are investigated and not progressions over a larger pressure range.…”

Section: -2mentioning

confidence: 88%

Experimental Investigation of Contact Heat Transfer at High Pressures

Göttlich¹,

Helmig²,

Gerhard³

et al. 2022

International Conference on Fluid Flow, Heat and Mass Transfer

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Besides the mechanical description of technical systems, a thermal modelling is frequently required. In this context, contact heat transfer coefficients are essential boundary conditions for the thermal simulation of technical systems consisting of several individual components. This parameter is mainly influenced by the surface structure and roughness of the contact partners as well as the applied contact pressure. However, although the influencing parameters are well known, an analytical determination is quite difficult. Therefore, an experimental quantification is mandatory. So far, experiments in literature have primarily focused on the investigation of contact heat transfers at moderate loads up to 100 MPa. Nevertheless, there are some applications where solids are in contact at very high pressure and resulting heat transfer between them plays an essential role, such as the interface between the tool and the workpiece during machining. The aim of this work is to present a novel experimental methodology to determine contact heat transfers at high loads. In this approach, infrared thermography is used to measure the temperature data, which is consequently used to solve an inverse problem using the conjugate gradient method, which provides the corresponding contact heat transfer coefficients. Furthermore, first experimental results for a load-dependent heat transfer for loads between 200 and 1200 MPa are presented and occurring effects are discussed.

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Section: -2mentioning

confidence: 88%

Experimental Investigation of Contact Heat Transfer at High Pressures

Göttlich¹,

Helmig²,

Gerhard³

et al. 2022

International Conference on Fluid Flow, Heat and Mass Transfer

View full text Add to dashboard Cite

show abstract

“…A more advanced implementation of the tool-embedded thermocouple was used by Kryzhanivskyy et al [82,83]. Their experiments included eight thermocouples embedded at different locations within the cutting tool to inform their FE model with heat flux as a parameter.…”

Section: Embedded Thermocouplesmentioning

confidence: 99%

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

Leonidas

Ayvar-Soberanis

Laalej

et al. 2022

Sensors

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During the machining process, substantial thermal loads are generated due to tribological factors and plastic deformation. The increase in temperature during the cutting process can lead to accelerated tool wear, reducing the tool’s lifespan; the degradation of machining accuracy in the form of dimensional inaccuracies; and thermally induced defects affecting the metallurgical properties of the machined component. These effects can lead to a significant increase in operational costs and waste which deviate from the sustainability goals of Industry 4.0. Temperature is an important machining response; however, it is one of the most difficult factors to monitor, especially in high-speed machining applications such as drilling and milling, because of the high rotational speeds of the cutting tool and the aggressive machining environments. In this article, thermocouple and infrared radiation temperature measurement methods used by researchers to monitor temperature during turning, drilling and milling operations are reviewed. The major merits and limitations of each temperature measurement methodology are discussed and evaluated. Thermocouples offer a relatively inexpensive solution; however, they are prone to calibration drifts and their response times are insufficient to capture rapid temperature changes in high-speed operations. Fibre optic infrared thermometers have very fast response times; however, they can be relatively expensive and require a more robust implementation. It was found that no one temperature measurement methodology is ideal for all machining operations. The most suitable temperature measurement method can be selected by individual researchers based upon their experimental requirements using critical criteria, which include the expected temperature range, the sensor sensitivity to noise, responsiveness and cost.

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