Inverse estimation of the tool-work interface temperature in end milling

Abstract

An inverse heat conduction problem of end milling is studied in this paper. The transient tool-face temperature and heat dissipation to the workpiece in the milling area are estimated by an inverse finite element method with the temperatures measured on the machined surface. A least square inverse scheme is applied to solve the unknown boundary at the tool-work interface based on the surface temperatures measured outside the cutting zone by an infrared (IR) pyrometer. An ellipsoidal mapping model is adopted for coordinate transformation of a moving heat source system, which is treated in a one-dimensional (1D) ellipsoidal coordinate. The numerical and experimental results show a good agreement in the estimation for the flame heating and end milling of steel and aluminum alloy.