Abstract
Elevated temperature in the machining process is detrimental to cutting tools—a result of the effect of thermal softening and material diffusion. Material diffusion also deteriorates the quality of the machined part. Measuring or predicting machining temperatures is important for the optimization of the machining process, but experimental temperature measurement is difficult and inconvenient because of the complex contact phenomena between tools and workpieces, and because of restricted accessibility during the machining process. This paper presents an original analytical model for fast prediction of machining temperatures at two deformation zones in orthogonal cutting, namely the primary shear zone and the tool–chip interface. Temperatures were predicted based on a correlation between force and temperature using the mechanics of the cutting process and material constitutive relation. Minimization of the differences between calculated material flow stresses using a mechanics model and a constitutive model yielded an estimate of machining temperatures. Experimental forces, cutting condition parameters, and constitutive model constants were inputs, while machining forces were easily measurable by a piezoelectric dynamometer. Machining temperatures of AISI 1045 steel were predicted under various cutting conditions to demonstrate the predictive capability of each presented model. Close agreements were observed by verifying them against documented values in the literature. The influence of model inputs and computational efficiency were further investigated. The presented model has high computational efficiency that allows real-time prediction and low experimental complexity, considering the easily measurable input variables.
Highlights
Machining is one of the most widely used manufacturing processes because of its fast speed and applicability to a broad class of materials
To further investigate the advantages and disadvantages of the presented model, machining temperatures were predicted in the orthogonal cutting of AISI 1045 steel under various cutting conditions
In this work, machining temperatures were predicted in the orthogonal cutting of AISI 1045 steel
Summary
Machining is one of the most widely used manufacturing processes because of its fast speed and applicability to a broad class of materials. The high computational cost and low computational efficiency of numerical methods have been major limitations preventing real-time prediction and optimization with process-parameter planning To overcome these limitations, analytical methods were developed that could predict machining processes with comparable accuracy along with considerably high computational efficiency [19,20]. The heat source caused by the friction between the tool and chip at the SSZ was observed by comparing the equivalence between two heat source solutions, namely a moving heat source in the chip and a stationary heat source in the tool This model was further developed by considering the thermal properties of tools and tool-wear under oblique cutting conditions [24,25]. The previous work used the chip-thickness and constant-material-flow-rate assumption that prevents real-time temperature prediction and optimized prediction accuracy [29]. Sufficient accuracy for inEmbedded thermocouple [7], situ/ post-processing tool–work thermocouple [8], infrared technique [9], measurement
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