Investigation of End-Milling Process Based on Monitoring Method with Wireless Telegraphic Multifunctional Tool Holder and Infrared Thermography

Abstract

Infrared thermographic technology has attracted the attention of various industrial fields. We therefore focus on it as a novel tool temperature monitoring method to improve the end-milling conditions of difficult-to-cut materials. However, it is difficult to measure tool temperature under coolant conditions because coolant prevents the monitoring of end-mill tool surfaces. Thus, we developed a novel temperature monitoring method by applying a pore electric discharge machining process to place a thermocouple sensor in the end-mill tool and by using a wireless telegraphic multifunctional tool holder to directly measure the internal temperature of the end-mill tool under rotation. We evaluated internal temperature distribution under various end-milling conditions on the basis of multipoint simultaneous measurements and discussed the influence of forced convection heat transfer on the internal temperature of the tool under various rotating conditions. In addition, we used a finite element method to analyze unsteady heat conduction on the basis of temperature measurement by high-speed video infrared thermography and compared the results with those of the wireless telegraphic multifunctional tool holder to demonstrate its validity and usefulness.