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On-line estimation of the tool-chip interface temperature field during turning using a sequential inverse method

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Abstract

It is well known that the direct measurement of temperature distribution at the tool-chip interface in a machining process is difficult to accomplish. Thus, this paper provides an on-line inverse technique to estimate the temperature field at the tool-chip interface of a turning tool, using temperatures measured at some sensor-accessible locations. A sequential Tikhonov regularization method (STRM) is proposed to determine the transient heat flux imposed at the tool-chip interface, by solving an inverse heat conduction problem (IHCP). Then, the temperature field at the tool-chip interface is computed by solving the three-dimensional non-linear thermal model, with a method combining Duhamel’s superposition theorem with the finite element method. The procedure proposed shows a superiority in on-line applications due to its high computational efficiency and independence of future measurements. A comparison of the STRM with several other inverse methods in the literature was made through numerical tests. Experimental cutting tests on Ti-6Al-4V titanium alloy were done to validate the thermal model and method. Both numerical and experimental tests show that the proposed method can provide an efficient and easy-to-implement strategy for on-line temperature field monitoring of machine tools.

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Funding

The work is supported by the National Natural Science Foundation of China granted under No. 51575215 and U1501248 and the National Basic Research Program of China (973 Program) granted under No. 2013CB035803.

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Authors and Affiliations

  1. State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, 430074, Hubei, People’s Republic of China

    Shuwen Huang, Bo Tao, Jindang Li, Yajun Fan & Zhouping Yin

Authors
  1. Shuwen Huang
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  2. Bo Tao
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  3. Jindang Li
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  4. Yajun Fan
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  5. Zhouping Yin
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Correspondence to Bo Tao.

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Huang, S., Tao, B., Li, J. et al. On-line estimation of the tool-chip interface temperature field during turning using a sequential inverse method. Int J Adv Manuf Technol 97, 939–952 (2018). https://doi.org/10.1007/s00170-018-1987-9

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  • DOI: https://doi.org/10.1007/s00170-018-1987-9

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