Advertisement

Investigation of temperature distribution in orthogonal cutting through dual-zone contact model on the rake face

  • Esin Cakir
  • Emre Ozlu
  • Mustafa Bakkal
  • Erhan Budak
ORIGINAL ARTICLE

Abstract

A two-dimensional analytical model to calculate the temperature distribution in orthogonal cutting with dual-zone contact on the rake face is presented. The study considers heat generation in the primary shear zone and on the rake face. The material behavior in the primary shear zone is represented by Johnson-Cook constitutive equation while the contact on the rake face is modeled by sticking and sliding friction zones. This new temperature distribution model is used to determine the maximum temperature on the rake face and two-dimensional temperature distribution in the chip and on the tool surface. The dual-zone contact model on the rake face and convection boundary condition on the flank face are the important contributions of this work. The simulation results of the developed model are compared with experimental results where a good agreement is demonstrated.

Keywords

Orthogonal cutting Temperature distribution Temperature measurement Dual-zone contact 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    Berliner EM, Krainov VP (1991) Analytic calculations of the temperature field and heat flows on the tool surface in metal cutting due to sliding friction. Wear 143:379–395CrossRefGoogle Scholar
  2. 2.
    Radulescu R, Kapoor SG (1994) An analytical model for prediction of tool temperature fields during continuous and interrupted cutting. J Manuf Sci Eng 116:135–143Google Scholar
  3. 3.
    Stephenson DA, Jen TC, Lavine AS (1997) Cutting tool temperatures in contour turning: transient analysis and experimental verification. J Manuf Sci Eng 119:494–501CrossRefGoogle Scholar
  4. 4.
    Komanduri R, Hou ZB (2000) Thermal modeling of the metal cutting process part I: temperature rise distribution due to shear plane heat source. Int J Mech Sci 42:1715–1752CrossRefzbMATHGoogle Scholar
  5. 5.
    Komanduri R, Hou ZB (2001) Thermal modeling of the metal cutting process part II: temperature rise distribution due to frictional heat source at the tool–chip interface. Int J Mech Sci 43:57–88CrossRefzbMATHGoogle Scholar
  6. 6.
    Komanduri R, Hou ZB (2001) Thermal modeling of the metal cutting process part III: temperature rise distribution due to the combined effects of shear plane heat source and the tool–chip interface frictional heat source. Int J Mech Sci 43:89–107CrossRefzbMATHGoogle Scholar
  7. 7.
    Huang Y, Liang SY (2005) Cutting temperature modeling based on non-uniform heat intensity and partition ratio. Mach Sci Technol 9:301–323CrossRefGoogle Scholar
  8. 8.
    Moufki A, Molinari A, Dudzinski D (1998) Modelling of orthogonal cutting with a temperature dependent friction law. J Mech Phys Solids 46:2103–2138CrossRefzbMATHGoogle Scholar
  9. 9.
    Majumdar P, Jayaramachandran R, Ganesan S (2005) Finite element analysis of temperature rise in metal cutting processes. Appl Therm Eng 25:2152–2168CrossRefGoogle Scholar
  10. 10.
    Ostafiev V, Kharkevich A, Weinert K, Ostafiev S (1999) Tool heat transfer in orthogonal metal cutting. J Manuf Sci Eng 121(4):541–549CrossRefGoogle Scholar
  11. 11.
    Grzesik W (2006) Determination of temperature distribution in the cutting zone using hybrid analytical-FEM technique. Int J Mach Tools Manuf 6:651–658CrossRefGoogle Scholar
  12. 12.
    Ulutan D, Lazoglu I, Dinc C (2009) Three-dimensional temperature predictions in machining processes using finite difference method. J Mater Process Technol 209:1111–1121CrossRefGoogle Scholar
  13. 13.
    Li KM, Liang SY (2006) Modeling of cutting temperature in near dry machining. J Manuf Sci Eng 128(2):416–424CrossRefGoogle Scholar
  14. 14.
    Smith AJR, Armarego EJA (1981) Temperature prediction in orthogonal cutting with a finite difference approach. Ann CIRP 30:9–13CrossRefGoogle Scholar
  15. 15.
    Lazoğlu İ, Altıntaş Y (2002) Prediction of tool and chip temperature in continuous and interrupted machining. Int J Mach Tools Manuf 42:1011–1022CrossRefGoogle Scholar
  16. 16.
    Ozlu E, Budak E, Molinari A (2009) Analytical and experimental investigation of rake contact and friction behavior in metal cutting. Int J Mach Tools Manuf 49:865–875CrossRefGoogle Scholar
  17. 17.
    Ozlu E (2008) Analytical modeling of cutting process mechanics and dynamics for simulation of industrial machining operations. (Dissertation), Sabanci University, IstanbulGoogle Scholar
  18. 18.
    Budak E, Ozlu E (2008) Development of a thermomechanical cutting process model for machining process simulations. CIRP Ann Manuf Technol 57:97–100CrossRefGoogle Scholar
  19. 19.
    Dudzinski D, Molinari A (1997) A modelling of cutting for viscoplastic materials. Int J Mech Sci 39:369–389CrossRefzbMATHGoogle Scholar
  20. 20.
    Çakır, E.; Ozlu, E.; Bakkal, M.; Budak, E. (2012). Modeling of temperature distribution in orthogonal cutting with dual-zone contact at rake face; 1st International Conference on Virtual Machining Process Technology, Montreal, CanadaGoogle Scholar
  21. 21.
    Blok H (1937) Theoretical study of temperature rise at surfaces of actual contact under oiliness lubricating conditions. Proc General Disc Lubr Lubr Inst Mech Eng 2:222–235Google Scholar
  22. 22.
    Takeuchi Y, Sakamoto M, Sata T (1981) Improvement of working accuracy of an NC lathe by compensation for the thermal expansion of tool. CIRP Ann Manuf Technol 30:445–449CrossRefGoogle Scholar
  23. 23.
    Ozisik N (1968) Boundary value problems of heat conduction. International Textbook Company, PennsylvaniaGoogle Scholar
  24. 24.
    Ozisik N. (1993) Heat conduction, Second Edition, WileyGoogle Scholar
  25. 25.
    Akbar F, Mativenga PT, Sheikh MA (2008) An evaluation of heat partition in the high-speed turning of AISI/SAE 4140 steel with uncoated and TiN-coated tools. Proc IMechE Part B: J Eng Manuf 222:759–771CrossRefGoogle Scholar
  26. 26.
    Bahi S, Nouari M, Moufki A, El Mansori M, Molinari A (2011) A new friction law for sticking and sliding contacts in machining. Tribol Int 44:764–771CrossRefGoogle Scholar
  27. 27.
    Longbottom JM, Lanham JD (2005) Cutting temperature measurement while machining—a review. Aircraft Eng Aerosp Technol 77(2):122–130CrossRefGoogle Scholar
  28. 28.
    Ivester, R.W., Kennedy, M., Stevenson, R., Thiele, J., Furness, R. and Athavale, S. (2000). Assessment of Machining Models: Progress Report 4, pp. 511–538Google Scholar
  29. 29.
    Arrazola PJ, Arriola I, Davies MA, Cooke AL, Dutterer BS (2008) The effect of machinability on thermal fields in orthogonal cutting of AISI 4140 steel. CIRP Ann Manuf Technol 57(1):65–68CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  • Esin Cakir
    • 1
  • Emre Ozlu
    • 2
  • Mustafa Bakkal
    • 1
  • Erhan Budak
    • 2
  1. 1.Faculty of Mechanical EngineeringIstanbul Technical UniversityIstanbulTurkey
  2. 2.Manufacturing Research LabSabanci UniversityIstanbulTurkey

Personalised recommendations