Empirical modelling for work piece temperature during end milling of inconel 625 using a green’s function approach based on dirac delta function

Abstract

Milling is a very versatile process for the manufacturing of dies and aerospace components. Especially in the manufacturing of thin walled components, the dimensional accuracy is greatly affected due to heat generation and deflection in the wall. Therefore, minimization of heat generation during milling by optimizing controllable input process parameters, leads to improved accuracy in thin walls. In the present study, an empirical model for work piece temperature by solving the non-homogeneous partial differential equation using Green’s function has been simplified with Dirac delta approach during the end milling of Inconel625 work-piece with the assumption of single-pass cutting and one-point observation. This technique is normally used for solving the complex higher-order partial differential equation, but it is rarely applied in the heat dissipation problem during manufacturing in the recent past. The empirical approach is more effective and accurate as compared to experimental approaches used earlier in the recent past. To verify the adequacy of the empirical model of work piece temperature, 9 conformational experiments have been performed at 3 different cutting speeds with a constant depth of cut 5 mm and feed per tooth 0.05 mm. A good compromise has been observed among the responses obtained among the results obtained from an empirical approach and experimental observations at different cutting speeds. However, by little modification and adding a small algorithm, this single pass problem can be implemented on the multi-pass problems and even can also be applied to complex shapes.