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Article
Modeling of Transient Thermal Conditions in Cutting
Author(s)
T. Augspurger, F. Klocke, B. Döbbeler, M. Brockmann, S. Gierlings and A. Lima
Full-Text PDF XML 1206 Views
DOI:10.17265/2159-5275/2017.03.001
Affiliation(s)
ABSTRACT
The
thermal conditions like the temperature distribution and the heat fluxes during
metal cutting have a major influence on the machinability, the tool lifetime,
the metallurgical structure and thus the functionality of the work piece. This
in particular applies for manufacturing processes like milling, drilling and
turning for high-value turbomachinery components like impellers, combustion
engines and compressors of the aerospace and automotive industry as well as
energy generation, which play a major role in modern societies.
However, numerous
analytical and experimental efforts have been conducted in order to understand
the thermal conditions in metal cutting, yet many questions still prevail. Most
models are based on a stationary point of view and do not include time dependent effects like in
intensity and distribution varying heat sources, varying engagement conditions
and progressive tool wear. In order to cover such
transient physics an analytical approach based on Green’s functions for the
solution of the partial differential equations of unsteady heat conduction in
solids is used to model entire transient temperature fields. The validation of
the model is carried out in orthogonal cutting experiments not only punctually
but also for entire temperature fields. For these experiments an integrated
measurement of prevailing cutting force and temperature fields in the tool and
the chip by means of high-speed thermography were applied. The
thermal images were analyzed with regard to thermodynamic energy balancing
in order to derive the heat partition between tool, chips and workpiece. The thus calculated heat
flow into the tool was subsequently used in order to analytically model the
transient volumetric temperature fields in the tool. The described methodology
enables the modeling of the transient thermal state in the cutting zone and
particular in the tool, which is directly linked to phenomena like tool wear and
workpiece surface modifications.
KEYWORDS
Metal cutting, infrared thermography, heat sources, transient temperature fields, model based on Green’s functions
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