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Development and application of a temperature measurement device using the tool-workpiece thermocouple method in turning at high cutting speeds

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Abstract

This work aims to study the functionality of a device made to establish electrical signal continuity in the tool-workpiece thermocouple circuit in turning of electrical conductive materials under high cutting speeds, and thus allows the acquisition of the electromotive force of the system. This electromotive force is correlated with the chip-tool interface temperature and can be used for the machining process control. The device used three brushes made of aluminium alloy as contact elements on the polished cross section of the machined bar that is close to its centre. Its main advantage is its ability to replace the toxic mercury, although it is an excellent conductor for this type of thermocouple circuit. Besides, it allows the employment of more severe machining conditions, without the need of changing the lathe’s original geometric features. The functionality of this device was evaluated by measuring the cutting temperature (Tc) in turning different aluminium alloys, after calibration of the tool-workpiece thermocouple system. The machining tests followed a full 2k factorial design and a central composite design (CCD), and the results were analysed with multiple regression, response surface, gradient level and vector curve methods, having as input variables (xi) the mechanical strength of the work material (alloy), cutting speed (Vc), depth of cut (doc), feed rate (f) and lubrication and cooling condition (dry, flood cooling and minimum quantity of cutting fluid (MQF)). The results showed that the three-brush device, within the cutting conditions investigated and the material’s hardness, allowed one to obtain the cutting temperature values (Tc) consistent with those found when turning aluminium alloys. The effects of the independent variables (Material strength, Vc, doc, f and Lubricant) on the chip-tool interface temperature were also quantified.

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Authors and Affiliations

  1. Federal Institute of Espírito Santo, São Mateus, ES, 29932-540, Brazil

    M. C. Santos Jr. & J. S. Araújo Filho

  2. Federal University of Uberlandia, /MG, Uberlândia, 38400-902, Brazil

    M. A. S. Barrozo & A. R. Machado

  3. Kansas State University, Manhattan, KS, 67401, USA

    M. J. Jackson

  4. Mechanical Engineering Graduate Program, Pontifícia Universidade Católica do Paraná – PUCPR, Curitiba, PR, 80215-901, Brazil

    A. R. Machado

Authors
  1. M. C. Santos Jr.
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  2. J. S. Araújo Filho
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  3. M. A. S. Barrozo
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  4. M. J. Jackson
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  5. A. R. Machado
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Correspondence to A. R. Machado.

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Santos, M.C., Araújo Filho, J.S., Barrozo, M.A.S. et al. Development and application of a temperature measurement device using the tool-workpiece thermocouple method in turning at high cutting speeds. Int J Adv Manuf Technol 89, 2287–2298 (2017). https://doi.org/10.1007/s00170-016-9281-1

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  • DOI: https://doi.org/10.1007/s00170-016-9281-1

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