Abstract
This paper shows the influence of the mesh size on the heat flux in the micromilling process. The definition of the heat flux was based on the inverse heat conduction method (IHCM), applying the finite element technique with the Eulerian–Lagrangian approach. The micromilling was simulated with a cutter of 0.5 mm and four mesh sizes. The input parameters were two feed rates, two cutting speeds, and two radial depths of cut. Experiments were designed to verify the more significant input parameters on the heat flux and temperature. The results demonstrated that the mesh size has great influence on the responses. The values for heat flux can vary more with the mesh size than with the cutting parameters. On the other hand, the cutting speed was the parameter with the least significance. The adjusted data using IHCM for temperature, heat flux, and the convection coefficient corresponded with the traditional values.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Aneiro F.M., Coelho R.T., Brandão L.C.: Turning hardened steel using coated carbide at high cutting speeds. J. Braz. Soc. Mech. Sci. Eng. 30(2), 104–109 (2008)
Coelho R.T., Brandão L.C., Malavolta A.T.: Experimental and theoretical study on work piece temperature when tapping hardened AISI AISI H13 using different cooling systems. J. Braz. Soc. Mech. Sci. Eng. 32(2), 154–159 (2010)
Coelho R.T., Brandão L.C.: Temperature and heat flux when tapping of the hardened Steel using different cooling systems. Ingeniare Revista Chilena de Ingeniería 17(2), 267–274 (2009)
Lazard M., Corvisier P.: Modeling of a tool during turning Analytical prediction of the temperature and of the heat flux at the tool’s tip. Appl. Therm. Eng. 24, 839–849 (2004)
Brandão L.C., Coelho R.T., Lauro C.H.: Contribution to dynamic characteristics of the cutting temperature in the drilling process considering one dimension heat flux. Appl. Therm. Eng. 31, 3806–3813 (2011)
Carslaw, H.S.; Jaeger, J.C.: Conduction of Heat in Solids, 2nd edn, p. 510. Oxford, London (1985)
de Sousa P.F.B., Borges V.L., Pereira I.C., da Silva M.B., Guimarães G.: Estimation of heat flux and temperature field during drilling process using dynamic observers based on Green’s function. Appl. Therm. Eng. 48, 144–154 (2012)
Luchesi V., Coelho R.Y.: An inverse method to estimate the moving heat source in machining process. Appl. Therm. Eng. 45(46), 64–78 (2012)
Pittalà à G.M., Monno M.: A new approach to the prediction of temperature of the workpiece of face milling operations of Ti–6Al–4V. Appl. Therm. Eng. 31, 173–180 (2011)
Iqbal, S.A.; Mativenga, P.T.; Sheikh, M.A.: An investigative study of the interface heat transfer coefficient for FE modeling of high speed machining. NED Univ. J. Res. 4/1, 44–58 (2009)
Wu J., Han R.D.: A new approach to predicting the maximum temperature in dry drilling based on a finite element model. J. Manuf. Process. 11, 19–30 (2009)
Brandão L.C., Coelho R.T., Rodrigues A.R.: Experimental and theoretical study of work piece temperature when end milling hardened steels using (TiAl)N-coated and PcBN-tipped tools. J. Mater. Process. Technol. 199(1 e 3), 234–244 (2008)
Umbrello D., Filice L., Rizzuti S., Micari F., Settineri L.: On the effectiveness of finite Element simulation of orthogonal cutting with particular reference to temperature prediction. J. Mater. Process. Technol. 189, 284–291 (2007)
Courbon C., Mabrouki T., Rech J., Mazuyer D., D’Eramo E.: On the existence of a thermal contact resistance at the tool-chip interface in dry cutting of AISI 1045: formation mechanisms and influence on the cutting process. Appl. Therm. Eng. 50(1), 1311–1325 (2013)
Wissmiller D.L., Pfefferkorn F.E.: Micro end mill tool temperature measurement and prediction. J. Manuf. Process. 11, 45–53 (2009)
Ng E., Aspinwall D.K.: Modelling of hard part machining. J. Mater. Process. Technol. 127, 222–229 (2002)
Lauro, C.H.: Numerical Analysis with Experimental Validation of Cutting Forces in Micromilling Process of Hardened Steels with Variation of Austenitic Grain Sizes, M.Sc. Thesis, Federal University of São João del Rei, 82 p. (in Portuguese)
Liu K., Melkote S.N.: Finite element analysis of the influence of tool edge radius on size effect in orthogonal micro-cutting process. Int. J. Mech. Sci. 49, 650–660 (2007)
Lai X., Li H., Lin Z., Ni J.: Modeling and analysis of micro scale Milling considering size effect, micro cutter edge radius and minimum chip thickness. Int. J. Mach. Tools Manuf. 48, 1–14 (2008)
Woon K.S., Rahman M., Fang F.Z., Neo K.S., Liu K.: Investigations of tool edge radius effect in micromachining: a FEM simulation approach. J. Mater. Process. Technol. 167, 316–337 (2007)
SANDVIK: “Catálogo de produtos”, 490 p. (in Portuguese) (2012)
Chen L., El-Wardany T.I., Nasr M., Elbestawi M.A.: Effects of edge preparation and feed when hard turning a hot work die steel with polycrystalline cubic boron nitride tools. CIRP Ann. Manuf. Technol. 55, 89–92 (2006)
Longère P., Dragon A.: Evaluation of the inelastic heat fraction in the context of microstructure-supported dynamic plasticity modelling. Int. J. Impact Eng. 35, 995–999 (2008)
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Ribeiro Filho, S.L.M., Gomes, M.O., Lauro, C.H. et al. Definition of the Temperature and Heat Flux in Micromilling of Hardened Steel Using the Finite Element Method. Arab J Sci Eng 39, 7229–7239 (2014). https://doi.org/10.1007/s13369-014-1281-6
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s13369-014-1281-6