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Procedia CIRP 46 (2016) 173 – 176
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
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
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
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
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
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
[1] Abukhshim NA, Mativenga PT, Sheikh MA. Heat generation and
200
temperature prediction in metal cutting: A review and implications for high
Temperature o C