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Determination of the heat flux to the workpiece during dry turning by inverse methods

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Abstract

Reducing metal machining costs and harmful effects to the environment are the main benefits of dry machining compared to the application of cooling lubricants during machining processes. The abandonment of any lubricants is causing higher temperatures of workpiece, chip, and tool. Thus, the temperature gradient varies with time and space over the workpiece, causing dimensional deviations and profile defects due to thermal expansion and shrinking. The aim of this work is to determine the heat flux to the workpiece from experimental data. The temperatures of the workpiece were measured during an orthogonal turning process of carbon steel (AISI 1045). An analogous thermal model is used to solve the ill-posed inverse heat conduction problem by the sequential estimation method, introduced by Beck et al. (Inverse heat conduction, Wiley, New York, 1985) and for the evaluation of the results. The heat flux to the workpiece could be used in further work as a basic boundary condition in finite element simulations to find an alternative tool path, which compensate thermally induced deviations and profile defects of the workpiece. The heat flux to the workpiece is calculated for different cutting velocities, feed rates, and the influence of TiN-coatings on cemented carbide tools. Cutting parameters have been identified to minimize the heat load on the workpiece in general and therefore reduce errors due to dry machining.

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Acknowledgments

The authors would like to thank the German Research Foundation (Deutsche Forschungsgemeinschaft, DFG) for the funding of the depicted research within the priority programme 1480 (SPP 1480). Further, the authors would like to thank Prof. Klocke and Hendrik Puls of the Laboratory for Machine Tools and Production Engineering (WZL), RWTH Aachen, for providing the turning machine and the support in performing the experiments.

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Authors and Affiliations

  1. Institute of Heat and Mass Transfer, RWTH Aachen University, Augustinerbach 6, 52056, Aachen, Germany

    M. Deppermann & R. Kneer

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  1. M. Deppermann
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  2. R. Kneer
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Correspondence to M. Deppermann.

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Deppermann, M., Kneer, R. Determination of the heat flux to the workpiece during dry turning by inverse methods. Prod. Eng. Res. Devel. 9, 465–471 (2015). https://doi.org/10.1007/s11740-015-0635-6

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  • DOI: https://doi.org/10.1007/s11740-015-0635-6

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