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Transient multi-domain thermal modeling of interrupted cutting with coated tools

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Abstract

Interrupted cutting operations, such as milling, produce fluctuating tool temperatures which directly affect the process outputs. Thus, prediction of cutting tool temperatures enables process planning, selection of materials for tool substrate and coating layers, and tool geometric design for improved productivity in machining operations. Theoretical analysis of temperature is a cost effective way to predict the tool temperatures. Considering the industrial needs, a theoretical model should be fast, easy to implement, and reliable. To that end, a novel hybrid model, which assembles analytical and numerical methods, is proposed in this study. This novel transient thermal model simulates the interrupted cutting with coated cutting tools. The proposed model includes an analytical heat flux calculation at the tool-chip interface considering the sticking-sliding contact behavior. The determined heat flux is, then, used to perform a numerical solution of the transient heat conduction problem in the cutting tool geometry with temperature-dependent thermal properties. The developed model is validated with experimental results found in literature under different cutting conditions. The results show that the model can predict the maximum temperatures generated in a thermal cycle with an accuracy of 2–10%. Thus, the proposed model can be further used to determine the process parameters, properties of coating layers, and tool geometric design.

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Abbreviations

A,B,C,n,ν:

Johnson-Cook material constants

γ :

Shear strain

\( \dot{\gamma} \) :

Shear strain rate (1/s)

\( {\dot{\gamma}}_0 \) :

Reference shear strain rate (1/s)

γ 1 :

Shear strain at the exit of the band

ϕ :

Shear angle

l c :

Total contact length (m)

l p :

Sticking length (m)

μ :

Sliding friction coefficient

P(x) :

Pressure distribution on rake face (Pa)

q "(x):

Heat flux into the tool (W/m2)

F t :

Tangential cutting force (N)

P t :

Cutting power (W)

b :

Width of cut (m)

ω :

Constant velocity distribution ratio

R t :

Cutting tool radius (m)

t :

Time (s)

t 1 :

Heating/cutting time (s)

t 2 :

Cooling/non-cutting time (s)

n :

Integer number

k, k 1 , k 2 :

Thermal conductivity (W/mK)

T :

Absolute temperature (K)

T r :

Reference temperature (K)

T m :

Melting temperature (K)

τ s :

Shear stress (Pa)

τ 0 :

Shear stress at the entry of the shear band (Pa)

τ 1 :

Shear stress at the exit of the shear band (Pa)

ρ :

Material density (kg/m3)

V :

Cutting speed (m/s)

V c :

Chip velocity (m/s)

V c0 :

Chip velocity constant (m/s)

V N :

Normal velocity component (m/s)

h 1 :

Uncut chip thickness (m)

T w :

Absolute temperature of workpiece (K)

β :

Taylor-Quinney coefficient

c :

Heat capacity of workpiece (J/kgK)

α :

Rake angle

λ a :

Apparent friction angle

ζ :

Stress distribution exponent

P 0 :

Normal pressure constant (N/m2)

μ a :

Apparent friction coefficient

a e :

Radial immersion/radial depth of cut (m)

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  1. Mechanical Engineering Department, Isik University, Istanbul, Turkey

    Umut Karaguzel

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Karaguzel, U. Transient multi-domain thermal modeling of interrupted cutting with coated tools. Int J Adv Manuf Technol 116, 345–361 (2021). https://doi.org/10.1007/s00170-021-07388-6

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