Conduction Heat Transfer in Manufacturing Processes

P M V Subbarao
Professor
Mechanical Engineering Department
I I T Delhi

Heat Transfer due to micro-molecular Movements!!!

 The thermal energy balance equation

The thermal energy balance equation for the volume V is then

~
h 

V
t
dV   .q ' ' dV   g (r , t )dV
V V

However, since the integrals are equal the arguments are also equal.
The most general form of the differential thermal energy balance
equation is ~
h 
 .q ' ' g (r , t )
t
This is called the differential thermal energy balance equation.
The fact is that it is not the heat generated by a machining process
that does the damage, it’s the increase in temperature.
 Constitutive Equation for The Heat Flux
• Fourier law of conduction in vector form is used as constitutive
equation to replace heat flux vector in terms of primitive
properties.

q ' '   kT

  T ˆ T ˆ T ˆ 
q ' '  k  i  j k
 x y z 
 The Conduction Equation

~
h 
 .q ' ' g (r , t )
t
Incorporation of the constitutive equation into the energy equation
above yields:
T
C p  . k .T  g (r , t )
t
Dividing both sides by Cp and introducing the thermal diffusivity
of the material given by

k m2 m
  m
C p s s
 Thermal Diffusivity, 

• Thermal diffusivity includes the effects of properties like

mass density, Thermal
thermal conductivity
Diffusivity ofand specific
general heat
Tools
capacity.
• The physical significance of thermal diffusivity is
associated with the diffusion of heat generated in shear
zone into the medium (tool body/chip body/work) with
time.
• The higher thermal diffusivity coefficient signifies the
faster penetration of the heat into the medium and the less
time required to remove the heat from the solid.
• Thermal diffusivity, which is involved in all unsteady heat-
conduction problems, is a property of the solid object.
• The time rate of change of temperature depends on its
numerical value.
 T  k  g (r , t )
 . .T  
t  C p  C p

T
 . .T 
g (r , t )
t C p
This is often called the heat equation.

For a homogeneous material:

T g ( x, t )
  T 
2

t C p
This is a general form of heat conduction equation.
Valid for all geometries.
Selection of geometry depends on nature of application.
 Geometry of Machining Systems : Heat Generation
•Anyone who is even casually
involved with a machining
process knows that cutting tools
generate large amounts of heat.

In fact, much of the power drawn at the spindle motor winds up as

heat which is concentrated in a very small area at the cutting edge
of the tool, and in the chip itself
•Heat is generated in three ways (locations);
•by the deformation of the metal in the shear zone ahead of the
cutting edge,
•at the point of separation when the metal is physically pulled apart
•by the friction of the chip as it rubs along the surface of the tool as
it is pushed out of the way..
General conduction equation based on Cartesian Coordinates

T
C p  .kT  g ( x, t )
t
For an isotropic and homogeneous material:
T
C p  k T  g ( x, t )
2

t

T   T  T  T
2 2 2
C p  k  2  2  2   g ( x, y, z : t )
t  x y z 
Geometry of Drilling Operation
 General conduction equation based on Polar
Cylindrical Coordinates

T
C p  kT   g ( x, t )
t

T    T  1   T    T 
C p  k r  2      g ( r ,  , z )
t  r  r  r     z  z 
 General conduction equation based on Polar
Spherical Coordinates

T  1   2 T  1   T  1  2T 
C p  k 2 r  2  sin   2 2 2
 g (r ,  ,  : t )
t  r r  r  r sin      r sin   