Machining processes are characterized by thermal loads generated during the shearing and friction work of the cutting process. For the in-process temperature measurement by a tool-workpiece thermocouple a consideration of the change in temperature of the cold junction at the specimen rear side is vital for the accuracy of the measurement. Thus, a macroscale thermodynamic simulation model implemented in COMSOL Multiphysics is used to model the heat distribution within the specimen during turning of the aluminum alloy EN AW-2017. The thermal input conditions are derived from experimental tests. For the assumption of the relative measurement error the simulated cold junction temperature is compared to the in-process temperature measured by a tool-workpiece thermocouple.The model shows that the machining time is the most important factor for heating of the cold junction. On the one hand, for low cutting speeds the measurement error in relation to the measured temperature is significantly high which discloses the need for a temperature compensation in this parameter range. On the other hand, for high cutting speeds and thus short machining times, the cold junction is not subjected to a significant increase in temperature. Consequently, the model validates the applicability of the temperature measurement based on a tool-workpiece thermocouple for dry machining of aluminum alloys with high cutting speeds.
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