Abstract
This work presents a developed thermal model of hard precision turning, in which the depth of the cut is made to be considerably smaller than the tool nose radius for final finishing. The required input data for this model was extracted from a previously published mechanistic model of precision turning. This mechanistic model is based on Merchant’s analysis of 3D cutting, which was modified to adopt the precision turning operation. Calculations were obtained of the shear plane temperature rise at the primary deformation zone and the temperature rise of the chip due to the work done in overcoming friction at the secondary deformation zone (frictional temperature rise). The thermophysical properties of the workpiece and cutting tool materials as well as their variation under different shear plane and frictional temperatures were considered. After performing the required calibrations, the cutting temperatures were measured with the tool-workpiece thermocouple technique during machining of hardened HSS and D2 tool steel by PCBN and mixed alumina ceramic tools. The occurrence of secondary hardening during HSS machining was found to be dependent on the thermal conductivity of the tool material. The estimated cutting temperatures were found to be reasonably close to the measured ones.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Komanduri R (1993) Machining and grinding—a historical review of classical papers. Appl Mech Rev 46:80–132. https://doi.org/10.1115/1.3121404
Abukhshim NA, Mativenga PT, Sheikh MA (2006) Heat generation and temperature prediction in metal cutting: a review and implications for high speed machining. Int J Mach Tools Manuf 46(7–8):782–800. https://doi.org/10.1016/j.ijmachtools.2005.07.024
Baohai W, Di C, Xiaodong H, Dinghua Z, Kai T (2016) Cutting tool temperature prediction method using analytical model for end milling. Chin J Aeronaut 29(6):1788–1794. https://doi.org/10.1016/j.cja.2016.03.011
Ng EG, Aspinwall DK (2002) The effect of workpiece hardness and cutting speed on the machinability of AISI H13 hot work die steel when using PCBN tooling. J Manuf Sci Eng 124(3):588–594. https://doi.org/10.1115/1.1452749
Kikuchi M (2009) The use of cutting temperature to evaluate the machinability of titanium alloys. Acta Biomater 5:770–775. https://doi.org/10.1016/j.actbio.2008.08.016
Díaz-Álvarez J, Cantero JL, Miguélez H, Soldani X (2014) Numerical analysis of thermomechanical phenomena influencing tool wear in finishing turning of Inconel 718. Int J Mech Sci 82:161–169. https://doi.org/10.1016/j.ijmecsci.2014.03.010
Devillez A, Le CG, Dominiak S, Dudzinski D (2011) Dry machining of Inconel 718, workpiece surface integrity. J Mater Process Technol 211:1590–1598. https://doi.org/10.1016/j.jmatprotec.2011.04.011
Díaz-Álvarez J, Tapetado A, Vázquez C, Miguélez H (2017) Temperature measurement and numerical prediction in machining Inconel 718. Sensors 17:1531. https://doi.org/10.3390/s17071531
Tönshoff HK, Arendt C, Ben Amor R (2000) Cutting of hardened steels. Ann CIRP 49(2):547–566. https://doi.org/10.1016/S0007-8506(07)63455-6
Shalaby MA, El Hakim MA, Abdelhameed MM, Krzanowski JE, Veldhuis SC, Dosbaeva GK (2014) Wear mechanisms of several cutting tool materials in hard turning of high carbon–chromium tool steel. Tribol Int 70:148–154. https://doi.org/10.1016/j.triboint.2013.10.011
Fox-Rabinovich G, Gershman I, Yamamoto K, Aguirre M, Covelli D, Arif T, Aramesh M, Shalaby M, Veldhuis S (2017) Surface/interface phenomena in nanomultilayer coating under severing tribological conditions. Surf Interface Anal 49(7):584–593. https://doi.org/10.1002/sia.6196
Ren XJ, Yang QX, James RD, Wang L (2004) Cutting temperatures in hard turning chromium hardfacings with PCBN tooling. J Mater Process Technol 147(1):38–44. https://doi.org/10.1016/j.jmatprotec.2003.10.013
Battaglia JL, Puigsegur L, Cahuc O (2005) Estimated temperature on a machined surface using an inverse approach. Exp Heat Transf 18(1):13–32. https://doi.org/10.1080/08916150590884826
Leshock CE, Shin YC (1997) Investigation on cutting temperature in turning by a tool work thermocouple technique. J Manuf Sci Eng 119(4A):502–508. https://doi.org/10.1115/1.2831180
Anagonye AU, Stephenson DA (2002) Modeling cutting temperatures for turning inserts with various tool geometries and materials. J Manuf Sci Eng 124(3):544–552. https://doi.org/10.1115/1.1461838
Bono M, Ni J (2002) A method for measuring the temperature distribution along the cutting edges of a drill. J Manuf Sci Eng 124(4):921–923. https://doi.org/10.1115/1.1511525
Ueda T, Al Huda M, Yamada K, Nakayama K, Kudo H (1999) Temperature measurement of CBN tool in turning of high hardness steel. CIRP Ann Manuf Technol 48(1):63–66. https://doi.org/10.1016/S0007-8506(07)63132-1
Al Huda M, Yamada K, Hosokawa A, Ueda T (2002) Investigation of temperature at tool-chip interface in turning using two-color pyrometer. J Manuf Sci Eng 124(2):200–207. https://doi.org/10.1115/1.1455641
Komanduri R, Hou ZB (2001) A review of the experimental techniques for measurements of heat and temperatures generated in some manufacturing processes and tribology. Tribol Int 34:653–682. https://doi.org/10.1016/S0301-679X(01)00068-8
Stephenson DA (1993) Tool-work thermocouple temperature measurements—theory and implementation issue. Transactions of the ASME, J Eng Ind-T Asme 115:432–437. https://doi.org/10.1115/1.2901786.20
Stephenson DA (1991) Assessment of steady-state metal cutting temperature models based on simultaneous infrared and thermocouple data. J Eng Ind 113(2):121–128. https://doi.org/10.1115/1.2899668
Stephenson DA, Agapiou JS (1997) Metal cutting theory and practice. Marcel Dekker, New York
Chen G, Ren C, Zhang P, Cui K, Li Y (2013) Measurement and finite element simulation of micro-cutting temperatures of tool tip and workpiece. Int J Mach Tool Manu 75:16–26. https://doi.org/10.1016/j.ijmachtools.2013.08.005
Maier T, Zaeh MF (2012) Modeling of the thermomechanical process effects on machine tool structures. Procedia CIRP 4:73–78. https://doi.org/10.1016/j.procir.2012.10.014
Nieslony P, Grzesik W, Laskowski P, Habrat W (2013) FEM-based modelling of the influence of thermophysical properties of work and cutting tool materials on the process performance. Procedia CIRP 8:3–8. https://doi.org/10.1016/j.procir.2013.06.056
Filice L, Umbrello D, Beccari S, Micari F (2006) On the FE codes capability for tool temperature calculation in machining processes. J Mater Process Technol 174:286–292. https://doi.org/10.1016/j.jmatprotec.2006.01.012
Umbrello D, Filice L, Rizzuti S, Micari F, Settineri L (2007) On the effectiveness of finite element simulation of orthogonal cutting with particular reference to temperature prediction. J Mater Process Technol 189(1–3):284–291. https://doi.org/10.1016/j.jmatprotec.2007.01.038
Komanduri R, Hou ZB (2000) Thermal modeling of the metal cutting process—part I: temperature rise distribution due to shear plane heat source. Int J Mech Sci 42(9):1715–1752. https://doi.org/10.1016/S0020-7403(99)00070-3
Komanduri R, Hou ZB (2001) Thermal modeling of the metal cutting process—part II: temperature rise distribution due to frictional heat source at the tool-chip interface. Int J Mech Sci 43(1):57–88. https://doi.org/10.1016/S0020-7403(99)00104-6
Moufki A, Molinari A, Dudzinski D (1998) Modeling of orthogonal cutting with a temperature dependent friction law. J Mech Phys Solids 46(10):2103–2138. https://doi.org/10.1016/S0022-5096(98)00032-5
Bahi S, Nouari M, Moufki A, El Mansori M, Molinari A (2011) A new friction law for sticking and sliding contacts in machining. Tribol Int 44(7–8):764–771. https://doi.org/10.1016/j.triboint.2011.01.007
Zhou F, Wang X, Hu Y, Ling L (2013) Modeling temperature of non-equidistant primary shear zone in metal cutting. Int J Therm Sci 73:38–45. https://doi.org/10.1016/j.ijthermalsci.2013.05.014
Li L, Li B, Ehmann KF, Li X (2013) A thermo-mechanical model of dry orthogonal cutting and its experimental validation through embedded micro-scale thin film thermocouple arrays in PCBN tooling. Int J Mach Tools Manuf 70:70–87. https://doi.org/10.1016/j.ijmachtools.2013.03.005
Shaw MC (2005) Metal cutting principles. Oxford University Press, New York
Polvorosa R, Suárez A, de Lacalle LNL, Cerrillo I, Wretland A, Veiga F (2017) Tool wear on nickel alloys with different coolant pressures: comparison of Alloy 718 and Waspalloy. J Manuf Process 26:44–56. https://doi.org/10.1016/j.jmapro.2017.01.012
Byrne G, Scholta E (1993) Environmentally clean machining processes—a strategic approach. CIRP Ann 42:471–474. https://doi.org/10.1016/S0007-8506(07)62488-3
Dudzinski D, Devillez A, Moufki A, Larrouquère D, Zerrouki V, Vigneau J (2004) A review of developments towards dry and high speed machining of Inconel 718 alloy. Int J Mach Tools Manuf 44:439–456. https://doi.org/10.1016/S0890-6955(03)00159-7
Canteli J, Cantero JL, Marín NC, Gómez B, Gordo E, Miguélez MH (2010) Cutting performance of TiCN-HSS cermet in dry machining. J Mater Process Technol 210:122–128. https://doi.org/10.1016/j.jmatprotec.2009.08.003
Shalaby MA, El Hakim MA, Veldhuis SC, Dosbaeva GK (2017) An investigation into the behavior of the cutting forces in precision turning. Int J Adv Manuf Technol 90(5–8):1605–1615. https://doi.org/10.1007/s00170-016-9465-8
El Hakim MA, Shalaby MA, Veldhuis SC, Dosbaev GK (2015) Effect of secondary hardening on cutting forces, cutting temperature, and tool wear in hard turning of high alloy tool steels. Measurement 65:233–238. https://doi.org/10.1016/j.2014.12.033
Abukhshim NA, Mativenga PT, Sheikh MA (2004) An investigation of the tool–chip contact length and wear in high-speed turning of EN19 steel. Proc Inst Mech Eng B J Eng Manuf 218:889–903. https://doi.org/10.1243/0954405041486064
Aleksandrovich AB, Danilenko BD, Loshchinin YV, Kolyadina TA, Khatsinskaya IM (1988) Thermophysical properties of low alloy high-speed steels. Metal Science and Heat Treatment 30(7):502–504. https://doi.org/10.1007/BF00777438
El Hakim M, Abad M, Abdelhameed M, Shalaby M, Veldhuis S (2011) Wear behavior of some cutting tool materials in hard turning of HSS. Tribol Int 44:1174–1181. https://doi.org/10.1016/j.triboint.2011.05.018
Dosbaeva GK, El Hakim MA, Shalaby MA, Krzanowski JE, Veldhuis SC (2015) Cutting temperature effect on PCBN and CVD coated carbide tools in hard turning of D2 tool steel. Int J Refract Metals Hard Mater 50:1–8. https://doi.org/10.1016/j.ijrmhm.2014.11.001
Funding
This work was carried out at the Machining Research Laboratory, Faculty of Engineering, Ain Shams University, Cairo, Egypt. It was supported by Natural Sciences and Engineering Research Council of Canada (NSERC) under the Canadian Network for Research and Innovation in Machining Technology (CANRIMT) Strategic Research Network Grant NETGP 479639-15.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Shalaby, M.A., El Hakim, M.A. & Veldhuis, S.C. A thermal model for hard precision turning. Int J Adv Manuf Technol 98, 2401–2413 (2018). https://doi.org/10.1007/s00170-018-2389-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-018-2389-8