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Thermal–mechanical model for machining with chamfered insert considering tool flank wear

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Abstract

The deformation of material leads to severe thermal–mechanical effects during metal cutting with chamfered insert. The high cutting temperature on the contact face results in the wear of the insert which is a critical issue. However, there is still a lack of a comprehensive understanding of thermal–mechanical effects, especially with respect to the presence of the tool flank wear. To address this, an analytical thermal–mechanical model is developed in this paper for the prediction of the temperature distribution with a worn insert based on a modified slip-line field approach. Firstly, an analytical slip-line field model is introduced based on material plasticity and plowing theory considering the tool flank wear. The structure of the slip-line field model, especially at the dead metal zone and the flank zone, is modified to reveal the material flow mechanism. Then, heat sources, including primary heat source, secondary heat source, tertiary heat source, and fourth heat source, are clarified to explain the heat generation phenomenon in the cutting process. In addition, a cutting temperature field model is developed to show the effect of tertiary heat source based on the imaginary heat source theory. Finally, the slip-line field geometry and temperature distribution are extracted from two-dimensional finite element simulation to verify the proposed model. And orthogonal experiments are carried out for measuring the maximum cutting temperature. The good agreement of predicted results, simulated results, and experimental results verifies the accuracy of the proposed model.

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Abbreviations

t :

Chip thickness

h :

Uncut chip thickness

l AB :

Chamfered length

l AC :

Length of the DMZ bottom edge

l AK :

Tool flank wear length

l BL :

Length of the tool-chip contact interface

ϕ :

Shear angle

β :

Rising angle of the DMZ bottom

ρ :

Prow angle

θ :

Slip-line angle

ξ 1 :

Friction factor angle at the tertiary deformation zone

ξ 4 :

Friction factor angle at the secondary deformation zone

F c :

Cutting force

F t :

Thrust force

k :

Material shear flow stress

τ AK :

Local shear flow stress at the flank-workpiece interface

τ AB :

Local shear flow stress at the DMZ-tool interface

τ BL :

Local shear flow stress at the chip-tool interface

λ w :

Thermal conductivity of workpiece

λ t :

Thermal conductivity of tool

a w :

Thermal diffusivity of workpiece

w :

Width of cut

V cu :

Cutting speed

V CD :

Shear velocity

V ch :

Chip velocity

V AC :

Velocity of material flow in DMZ-workpiece interface

V AK :

Velocity of material flow in flank-workpiece interface

Q 1 :

Intensity of primary heat source

Q 2 :

Intensity of secondary heat source

Q 3 :

Intensity of tertiary heat source

Q 4 :

Intensity of fourth heat source

T w :

Predicted temperature rise in the workpiece

T c :

Predicted temperature rise in the chip

T t :

Predicted temperature rise in the tool

R :

Distance from the measured point to each heat source element

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Funding

This work was supported by the National Natural Science Foundation of China (52175482) and the State Key Laboratory of Digital Manufacturing Equipment and Technology (DMETKF2021005).

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Authors and Affiliations

  1. Hubei Digital Manufacturing Key Laboratory, School of Mechanical and Electronic Engineering, Wuhan University of Technology, Wuhan, China

    Kejia Zhuang, Xin Yao, Cheng Hu & Chaoqun Wu

  2. Xiamen Golden Egret Special Alloy Corporation Limited, Xiamen, 361000, China

    Lingli Zou & Fengtian Lin

Authors
  1. Kejia Zhuang
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  2. Xin Yao
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  3. Cheng Hu
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  4. Lingli Zou
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  5. Fengtian Lin
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Contributions

Kejia Zhuang: supervision, original idea, manuscript writing. Xin Yao: manuscript writing, data collection. Cheng Hu: original idea, manuscript writing. Lingli Zou: data collection. Fengtian Lin: data collection. Chaoqun Wu: reviewing and editing.

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Correspondence to Kejia Zhuang.

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Zhuang, K., Yao, X., Hu, C. et al. Thermal–mechanical model for machining with chamfered insert considering tool flank wear. Int J Adv Manuf Technol 123, 3455–3471 (2022). https://doi.org/10.1007/s00170-022-10303-2

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  • DOI: https://doi.org/10.1007/s00170-022-10303-2

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