Abstract
During the metal cutting operation, heat generation at the cutting interface and the resulting heat distribution among tool, chip, workpiece, and cutting environment has a significant impact on the overall cutting process. Tool life, rate of tool wear, and dimensional accuracy of the machined surface are linked with the heat transfer. In order to develop a precise numerical model for machining, convective heat transfer coefficient is required to simulate the effect of a coolant. Previous literature provides a large operating range of values for the convective heat transfer coefficients, with no clear indication about the selection criterion. In this study, a coupling procedure based on finite element (FE) analysis and computational fluid dynamics (CFD) has been suggested to obtain the optimum value of the convective heat transfer coefficient. In this novel methodology, first the cutting temperature was attained from the FE-based simulation using a logical arbitrary value of convective heat transfer coefficient. The FE-based temperature result was taken as a heat source point on the solid domain of the cutting insert and computational fluid dynamics modeling was executed to examine the convective heat transfer coefficient under similar condition of air interaction. The methodology provided encouraging results by reducing error from 22 to 15% between the values of experimental and simulated cutting temperatures. The methodology revealed encouraging potential to investigate convective heat transfer coefficients under different cutting environments. The incorporation of CFD modeling technique in the area of metal cutting will also benefit other peers working in the similar areas of interest.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Trent EM, Wright PK (2000) Metal Cutting, 4th edn. Butterworth–Heinemann, Boston
Abukhshim NA, Mativenga PT, Sheikh MA (2005) Investigation of heat partition in high speed turning of high strength alloy steel. Int J Mach Tools Manuf 45(15):1687–1695
Carvalho SR, Lima e Silva SMM, Machado AR, Guimarães G (2006) Temperature determination at the chip–tool interface using an inverse thermal model considering the tool and tool holder. J Mater Process Technol 179(1–3):97–104
Liang L, Xu H, Ke Z (2013) An improved three-dimensional inverse heat conduction procedure to determine the tool-chip interface temperature in dry turning. Int J Therm Sci 64:152–161
Pervaiz S, Deiab I, Wahba E, Rashid A, Nicolescu CM (2015) A novel numerical modeling approach to determine the temperature distribution in the cutting tool using conjugate heat transfer (CHT) analysis. Int J Adv Manuf Technol 80(5):1039–1047
Miller MR, Mulholland G, Anderson C (2003) Experimental cutting tool temperature distributions. ASME J Manuf Sci Eng 125:667–673
Stephenson DA (1993) Tool-work thermocouple measurements—theory and implementation issues. ASME J Eng Ind 115:432–437
Shaw MC (1984) Metal cutting principles. Clarendon Press, Oxford
Stephenson DA (1992) Tool-work thermocouple temperature measurements: theory and implementation issues, in Proceedings of Winter Annual Meeting of ASME, pp. 81–95
O’Sullivan D, Cotterell M (2001) Temperature measurement in single point turning. J Mater Process Technol 118:301–308
Kottenstette JP (1986) Measuring tool-chip interface temperatures. ASME J Eng Ind 108(2):101–104
Ueda T, Sato M, Nakayama K (1998) The temperature of a single crystal diamond tool in turning. CIRP Ann Manuf Technol 47:41–44
Grzesik W, Nieslony P (2000) Thermal characterization of the chip-tool when using coated turning inserts. J Manuf Process 2(2):380
M’Saoubi R, Lebrun JL, Changeux B (1998) A new method for cutting tool temperature measurement using Ccd infrared technique: influence of tool and coating. Mach Sci Technol 2(2):369–382
M’Saoubi R, Chandrasekaran H (2011) Experimental study and modelling of tool temperature distribution in orthogonal cutting of AISI 316L and AISI 3115 steels. Int J Adv Manuf Technol 56(9–12):865–877
Tay AAO (1993) A review of methods of calculating machining temperature. J Mater Process Technol 36:225–257
Chen M, Sun FH, Wang HL, Yuan RW, Qu ZH (2003) Experimental research on the dynamic characteristics of the cutting temperature in the process of highspeed milling. J Mater Process Technol 138:468–471
Ohadi MM, Cheng KL (1993) Modeling of temperature distributions in the workpieoe during abrasive waterjet machining. J Heat Transf 115:446–452
Lima FRS, Machado AR, Guimarães G (2001) Experimental heat flux and cutting temperature estimation, in Proceedings of the Third International Conference on Metal Cutting and High Speed Machining, pp. 25–34
Yen DW, Wright PK (1986) A remote temperature sensing technique for estimating the cutting interface temperature distribution. J Eng Ind 108:252–263
Kwon P, Shiemann T, Kountanya R (2001) An inverse estimation scheme to measure steady-state tool-chip interface temperatures using an infrared camera. Int J Mach Tools Manuf 41(7):1015–1030
Yvonnet J, Umbrello D, Chinesta F, Micari FA (2006) Simple inverse procedure to determine heat flux on the tool in orthogonal cutting. Int J Mach Tools Manuf 46:820–827
Luchesi VM, Coelho RT (2012) Experimental investigations of heat transfer coefficients of cutting fluids in metal cutting processes: analysis of workpiece phenomena in a given case study. Proc Inst Mech Eng Part B J Eng Manuf 226(7):1174–1184
Vazquez E, Kemmoku DT, Noritomi PY, da Silva JVL, Ciurana J (2014) Computer fluid dynamics analysis for efficient cooling and lubrication conditions in micromilling of Ti6Al4V alloy. Mater Manuf Process 29(11–12):1494–1501
Verma N, Manojkumar K, Ghosh A (2017) Journal of Materials Processing Technology Characteristics of aerosol produced by an internal-mix nozzle and its influence on force, residual stress and surface finish in SQCL grinding. J Mater Process Tech 240:223–232
Tanveer A, Marla D, Kapoor SG (2016) TI-6AL-4V alloy with an atomization-based cutting fluid spray, in Proceedings of the ASME 2016 International Manufacturing Science and Engineering Conference, MSEC2016, pp. 1–10
Kundrák J, Gyáni K, Tolvaj B, Pálmai Z, Tóth R (2017) Simulation modelling practice and theory thermotechnical modelling of hard turning: a computational fluid dynamics approach. Simul Model Pract Theory 70:52–64
Kishawy HA (May 2002) An experimental evaluation of cutting temperatures during high speed machining of hardened D2 tool steel. Mach Sci Technol 6(1):67–79
Pervaiz S (2015) Numerical and experimental investigations of the machinability of Ti6AI4V: energy efficiency and sustainable cooling/lubrication strategies, KTH, School of Industrial Engineering and Management (ITM)
Özel T, Llanos I, Soriano J, Arrazola PJ (2011) 3D finite modeling of chip formation process for machining Inconel 718: comparison of FE software predictions. Mach Sci Technol 15:21–46
Cockroft MG, Latham DJ (1968) Ductility and workability of metals. J Inst Met 96:33–39
ANSYS, Inc (2009) ANSYS CFX Solver Theory Guide. USA
Arpaci VS (1966) Conduction heat transfer. Addison-Wesley Publishing Company, Massachusetts
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Pervaiz, S., Deiab, I., Wahba, E. et al. A numerical and experimental study to investigate convective heat transfer and associated cutting temperature distribution in single point turning. Int J Adv Manuf Technol 94, 897–910 (2018). https://doi.org/10.1007/s00170-017-0975-9
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-017-0975-9