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The development of a hybrid cutting model for workpiece temperature distribution via advection heat partition approach

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Abstract

This paper presents a novel hybrid cutting model for the prediction of workpiece temperature distribution during the dry milling process of compacted graphite iron (CGI). The hybrid model consists of an analytical force model based on a mechanistic approach and finite element analysis (FEA) based on the thermal model. The heat generated during the milling process transferred to the workpiece is computed via the advection heat partition model. The workpiece temperature distribution obtained through the heat loads, using as boundary conditions in the FEA, was calculated by means of cutting forces. The developed force and thermal models have been experimentally validated, and good agreement between the measured and calculated results has been observed. The energy and active work calculations show that by doubling the feed during CGI milling, an energy saving of about 10% is achieved despite almost doubling the cutting forces.

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Acknowledgements

We are thankful for the support received from The Scientific and Technological Research Council of Türkiye.

Authors’ contribution

All three authors contributed to the study equally and read and approved the final manuscript.

Funding

This work was supported by the TÜBİTAK 1002-Short Term R&D Funding Program (121M985).

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Authors and Affiliations

  1. Mechanical Engineering Department, Istanbul Technical University, 34437, Istanbul, Turkey

    Mehmet Emre Kara & Mustafa Bakkal

  2. Mechanical Engineering Department, Isik University, 34980, Istanbul, Turkey

    Ali Taner Kuzu

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  1. Mehmet Emre Kara
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  2. Ali Taner Kuzu
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  3. Mustafa Bakkal
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Correspondence to Mehmet Emre Kara.

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Kara, M.E., Kuzu, A.T. & Bakkal, M. The development of a hybrid cutting model for workpiece temperature distribution via advection heat partition approach. Int J Adv Manuf Technol 126, 4283–4295 (2023). https://doi.org/10.1007/s00170-023-11393-2

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