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Procedia CIRP 46 (2016) 173 – 176

7th HPC 2016 – CIRP Conference on High Performance Cutting

Modeling and measurement of cutting temperatures in milling


Umut Karaguzela*, Mustafa Bakkala, Erhan Budakb
a
Mechanical Engineering Department, Istanbul Technical University, 34437 Istanbul, Turkey
b
Faculty of Engineering and Natural Sciences, Sabanci University, 81474 Istanbul, Turkey
* Corresponding author. Tel.: +902122931300; fax: +902122450795. E-mail address: karaguzelu@itu.edu.tr

Abstract

Milling is the one of most common cutting operations in industry. Interrupted nature of the milling process allows use of higher speeds which in
turn improves productivity. Cutting temperature is one of the key factors to be investigated in process optimization. In milling, cutting temperature
analysis is harder compared to turning due to experimentation difficulties and transient characteristics. In this study, a new experimental technique
is proposed to measure the face milling temperatures which are used to verify the analytical model developed. Results indicate a good agreement
between the model predictions and dry cutting experiments at different cutting speeds.

©©2016
2016TheTheAuthors. Published
Authors. by Elsevier
Published B.V This
by Elsevier B.V. is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the International Scientific Committee of 7th HPC 2016 in the person of the Conference Chair Prof.
Peer-review under responsibility of the International Scientific Committee of 7th HPC 2016 in the person of the Conference Chair
Matthias Putz.
Prof. Matthias Putz
Keywords: Milling; Cutting Tool; Temperature; Measurement

1. Introduction production. On the other hand measuring cutting temperature


can provide useful data to verify the proposed models, and can
Machining operations can be divided into two fundamental also be used in online monitoring.
groups as continuous and interrupted cutting. Milling is an
interrupted cutting operation which is used to generate a flat or In the machining literature the majority of the work is on
a three-dimensional free-formed surface. In case of any continuous cutting whereas there is only limited number of
machining operation high temperatures occur due to excessive studies on interrupted cutting. Chakraverti et al. [3] proposed a
amount of plastic deformation and friction between tool, chip unidimensional model to predict tool temperature distribution
and workpiece [1]. It is stated that most of the power (90-95%) during intermittent cutting in which the heat flux is assumed as
generated in a machining operation is converted to heat [2]. a periodic rectangular wave. It was found in the study that
Generated heat dissipates into tool, workpiece and chip which thermal stresses increase as amplitude of temperature
determines the tool life and the surface integrity of the finished fluctuation increases. Palmai [4] claimed that in interrupted
part as well as the machined part quality. Thus, in order to cutting, temperature increases with cutting speed up to a certain
improve productivity, thermal analysis of machining operation limit and this relationship can be defined with an empirical
is worth to investigate scientifically. formula. Stephenson and Ali [5] developed an analytical model
using Green’s functions to calculate the tool temperatures
It requires great effort to measure and predict the during interrupted cutting. In order to validate their model, they
temperatures experienced in machining due to characteristics of performed a series of experiments and measured cutting
the operation such as high speeds, number of parameters, size temperature by tool-workpiece thermocouple technique. They
of the heat generation zone etc. Process modeling of cutting concluded that the temperatures in interrupted cutting are lower
temperature contributes to determine the effects of cutting than those obtained in continuous cutting. Another analytical
parameters and select them to achieve more effective model was proposed by Radulescu et al. [6]. In their study,

2212-8271 © 2016 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the International Scientific Committee of 7th HPC 2016 in the person of the Conference Chair
Prof. Matthias Putz
doi:10.1016/j.procir.2016.03.182
174 Umut Karaguzel et al. / Procedia CIRP 46 (2016) 173 – 176

cutting temperatures on tool are calculated by using prescribed as equal to room temperature.
heat flux taking into account the convection to surrounding air.
The proposed model could be used for both interrupted and
continuous cutting. Islam et al. [7] introduced a finite difference
model which can calculate transient and steady state Workpiece
temperatures in chip, tool and workpiece. Tool

Measuring cutting tool temperature is a significant challenge Insert


in milling operation due to tool rotation. Wang et al. [8] used a
garter spring pickup and thermocouples located in the inserts to
measure the tool temperature. They investigate the effect of
number of teeth on the temperature, and concluded that
increasing number of inserts caused increased cutting
temperature. McFeron et al. [9] measured the average tool-chip
interface temperatures using a tool-workpiece thermocouple. Y Flank
Rake
Ueda et al. [10] developed a technique which includes a two- face
face
color pyrometer and two optical fibers one is rotating with tool
insert and the other one is stationary located in tool spindle to
Z
measure the tool temperature. Kerrigan et al. [11] used a
wireless telemetric system which is designed with tool holder
to measure the cutting temperatures during milling of CFRP
Ly
composites by a coupled thermocouple.
X
Lx
This paper presents a novel experimental technique to
measure transient tool temperatures in dry milling operation
with a K type thermocouple. Additionally, an analytical model Fig. 1. Geometrical representation of tool temperature model
is proposed which uses Green’s functions to solve the 3D
transient heat conduction problem. The proposed experimental Eq.(2) can be solved either analytically or numerically.
According to Stephenson [5], Green's functions can be used to
technique was used to verify the results obtained by the model.
solve this equation analytically if the cutting tool is assumed to
be as a semi-infinite rectangular volume heated from its corner.
2. Cutting tool temperature model
Then, the Green function θG , which represents the temperature
at the location (x, y, z) at time t, due to an instantaneous heat
Generated heat in cutting operation can be predicted by point source, located at x = xp, y = yp, z = 0, and releasing its
calculated cutting forces. Heat generation Q can be calculated energy at time t=τ.
as follows by assuming that all the mechanical work done in
machining operation is converted into heat energy [1]: 2 ª z2 º
TG ( x, y , z , x p , y p ,0, D ) exp « 2 »
Q FR .Vc (1) ( S .D ) 3
¬D ¼
ª § ( x  x p ) 2 · § ( x  x p ) 2 · º
Where FR is the resultant cutting force, Vc is the cutting speed. . «exp ¨ ¸  exp ¨ ¸¸ » (4)
«¬ ¨ 2 ¸ ¨ D2
Assuming that thermal properties of cutting tool are © D ¹ © ¹ »¼
homogeneous and independent of time, three dimensional heat ª § ( y  y p ) 2 · § ( y  y p ) 2 · º
diffusion equation in Cartesian coordinates is derived as: . «exp ¨
¨ 2 ¸¸  exp ¨¨ ¸¸ »
«¬ © D ¹ © D2 ¹ »¼
w 2T w 2T w 2T U c p wT
  (2)
wx 2 wy 2 wz 2 k wt where D 2 [D (t  W )]

where k is the thermal conductivity of the tool material, ρ is The temperature field for the tool can be obtained by using
the density, cp is the thermal capacity and T is the temperature heat flux function and integrating Eq. (4) over time, Lx and Ly.
field .
D t Lx Ly

In milling operation, a cutting insert is exposed to cyclic


T ( x, y , z , t )
k ³³ ³
0 0 0
TG ( x, y, z, x p , y p ,0, D).Q( x p , y p ,W )dy p dx p dW
heating and cooling periods, the heated area which is the tool- (5)
chip interface during cutting, is seen in Fig. 1. Hence the
boundary condition for the problem in Eq. (2) is determined as: The integration of θG over Lx and Ly can be denoted as θGR
and can be solved as follows:
wT
k q( x, y, t ) z 0; 0 d x d Lx , 0 d y d Ly (3) Lx Ly
wz TGR ( x, y, z , Lx , Ly , D) ³ ³
0 0
TG ( x, y, z, x p , y p ,0, D) dy p dx p

where Lx and Ly are the dimensions of the heat source area 1 ª z2 º
which can be seen in Fig. 1 and q(x,y,t) is the heat flux applied exp « 2 » TGU ( x, Lx , D).TGU ( y, Ly , D) (6)
2 SD ¬D ¼
on the xy surface. The other boundary surfaces are assumed as
insulated and the initial temperature for the body is considered
Umut Karaguzel et al. / Procedia CIRP 46 (2016) 173 – 176 175

where T GU (u , L, D ) erf §¨ L  u ·¸  erf §¨ L  u ·¸


400
© D ¹ © D ¹ h=10W/mK
350 h=100W/mK
By substitution of Eq. (6) in Eq. (5), temperature field for h=1000W/mK
cutting tool insert is derived in Eq.(7). 300
h=10000W/mK

Temperature o C
D t 250
T ( x, y , z , t )
k ³T
0 GR ( x, y, z, Lx , Ly , D).q(W )dW (7)
200
Eq. (7) includes two different expressions which are function 150
of time, θGR and q(τ) . Therefore, Eq. (7) can be solved by
convolution of time. 100

Vc=100m/min 50
a)
800 Vc=200m/min 0
0.5 1 1.5 2
Vc=300m/min
Temperature C

Time (sec)
o

600
Fig. 3. Effect of convection on tool temperature

400 Fig.3 shows the effect of convection coefficient on tool


temperature where the other cutting parameters are kept
200 constant as it is seen from the figure that up to a certain value
the effect can be negligible. Therefore, in Section 4, the
adiabatic boundary conditions are assumed in the calculations.
1.2 1.4 1.6 1.8
Time (sec) 3. Experimental study
b) full immersion
600 In order to verify the proposed model, a series of cutting
50% immersion
500 25% immersion experiments have been performed to measure the tool
Temperature o C

temperature. Measuring transient temperatures occurred in


400 milling operation is a significant challenge. To overcome this
300 problem a novel experimental setup is developed and applied
to milling operation.
200

100

0 Cutting tool
2.4 2.6 2.8 3 3.2 3.4 3.6 Data aqusition
Time (sec) system
Workpiece
Fig. 2. Effect of (a)cutting speed and (b)radial depth of cut on tool Connector
temperature

Thermocouple
Fig. 2 shows the solution of Eq. (7) with results of different
parameters where the other parameters are as follows: up- Insert
milling, depth of cut 1mm, feed per tooth 0.15 mm and kTool 65
W/mK. In Fig. 2a effect of cutting speed on tool temperature
is demonstrated. As the cutting speed increases, the elapsed
Dynamometer
time for one revolution of tool decreases. However , tool
temperature increases due to increasing in generated heat. Fig. 4. Experimental setup
Additionally, Fig. 2b shows the effect of radial depth of cut on
tool temperature. Radial depth of cut determines the elapsed Fig. 4 shows the experimental setup used in milling tests.
time during heating and cooling cycles. The heating cycles The setup includes a miniature data acquisition system (DAS)
become longer whereas cooling time reduces with immersion. rotating with tool holder during cutting mounted by screws, a
The model described above has adiabatic boundary connector and a K type thermocouple located at x=1mm,
conditions. Thus, a more realistic analytical model which y=2mm and z=0.3 mm. The thermocouple is embedded to the
includes convective boundary conditions is also developed cutting insert and located near the cutting zone. The details of
which again uses Green's function to solve related partial the cutting insert can be seen in Fig. 5. The DAS is an off-the-
differential equations. shelf-item with 500k sampling rate. The measured data is
stored in the device during cutting operation.
176 Umut Karaguzel et al. / Procedia CIRP 46 (2016) 173 – 176

Φ 0.8 mm 200

Temperature o C
150
Thermocouple
100
0.3 mm
Tool holder 50 simulation
experiment
0
Fig. 5. Details of cutting insert and thermocouple 2.6 2.8 3 3.2 3.4
Time (sec)
In milling tests 1050 steel was used as workpiece whereas Fig. 7. Experimental verification of model at Vc=75m/min
cutting insert was uncoated carbide insert with a grade AP20F.
Two different cutting speeds were selected whereas feed per 5. Conclusions
tooth and depth of cut were kept constant as 0.15 mm/rev and
1 mm, respectively. The cutting has 80 mm diameter, only one This paper presents an analytical model based on Green’s
cutting tooth was used during experiments. Additionally functions. Effect of convective boundary condition is added to
cutting forces were measured by a 3 axis dynamometer. the model. The proposed model shows that the effect of
convection is negligible under dry cutting conditions. It is also
4. Results and discussion presented that the developed experimental method to verify the
model is capable of measuring transient temperature occurred
The novel experimental setup described above is used to in milling operation. Further study will cover the heat
verify the proposed 3D transient heat conduction model. Fig.6 distribution on cutting zone and measurement of temperatures
shows the comparison between experimental results and during cutting of different materials under various parameters.
simulation at a cutting speed of 50 m/min. It can be seen from
this figure that there is a good match between prediction and Acknowledgement
measurement results. This cutting speed leads to a time period
of 0.3 sec. due to it’s a full immersion test whereas heating and The authors would like to thank the BAP, the project
cooling periods are both 0.15 sec. In the analysis average funding office of Istanbul Technical University.
cutting force is used to calculate the heat flux which is 866 N
and the partition ratio into tool is 9.6%. References

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temperature prediction in metal cutting: A review and implications for high
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