Professional Documents
Culture Documents
A R T I C L E I N F O A B S T R A C T
Keywords: Determination of the temperatures during machining is one of the most important challenges for
Temperature
accurate milling simulations. Coupled with excessive shearing, plastic deformation and friction in a small
Milling
region of cutting, the temperatures in milling may have very signicant impact on parts and tools such as
Modelling
dimensional errors, residual stresses and tool wear. Temperature exhibits a non-linear complex-
modelling problem in milling process. In this article, for the rst time, a novel thermal modelling is
introduced for fast and accurate prediction of temperatures in end milling processes. A theoretical
modelling approach and experimental validations are presented for various cutting conditions.
2014 CIRP.
http://dx.doi.org/10.1016/j.cirp.2014.03.072
0007-8506/ 2014 CIRP.
114 I. Lazoglu, B. Bugdayci / CIRP Annals - Manufacturing Technology 63 (2014) 113116
t h V w sinbn
Force modelling is very important input for precise thermal Q f F f V c (5)
model of end milling. The effects of the bottom cutting edge of the cosfn bn an sinfn an
tool must also be taken into account. Therefore, side and bottom where F s , F f , V w , V s and V c are the shear force in the shear plane,
cutting forces are determined separately and then integrated in the the frictional force between the tool rake face and the chip, the
model. The total cutting forces are the sum of side edge cutting cutting velocity, the component of cutting velocity along the shear
forces (~
F S ) and bottom edge cutting forces (~
F B ). plane and the component of cutting velocity along the rake face,
respectively. t , fn , an and bn are the shear stress in the shear plane,
~
F~
FS ~
FB (1) shear angle, normal rake angle and normal friction angle,
respectively.
For the modelling of the side edge, the tool is divided into discs The frictional heat ow rate into the tool per unit area is given as
in the axial direction. The contributions of these elements are follows
calculated separately for each ute and rotation angle. The
contribution of each disc for a given angular immersion position Bt Q f
Q t (6)
(u) is as the following: lcn kt
2 3 where Bt is the recursively determined heat partition into tool, kt is
dF S;T;i; j u
the tool thermal conductivity and
dF S;i; j dF S;R;i; j u 5
4
dF S;Z;i; j u hsechc sinun fn
82 3 2 39 lcontact (7)
< K Sc;T;i; j K Se;T;i; j = sinfn cosan cosun sinan sinun
4 K Sc;R;i; j hS;i; j u K Se;R;i; j 5 wS;i; j
5 4 (2)
: ; is the toolchip contact length, h; an ; hc are the uncut chip
K Sc;Z;i; j K Se;Z;i; j
thickness, the normal rake angle and the chip ow angle, and
In this equation, dFS,i,j is the differential side edge cutting force fn ; un are the normal shear angle and the resultant cutting force
acting on the ith ute at the jth disc along the depth of cut, and oblique angle, respectively.
consists of three components in the radial (R), tangential (T) and The heat balance equation per innitesimal volume can be
axial (Z) directions. The value of each cutting force component written by the following partial differential equation,
depends on the cutting force coefcients (KSc,T,i,j, KSc,R,i,j, KSc,Z,i,j) due
d2 T d2 T d2 T q rC p @T @x @T @y @T @z
to shearing and cutting force edge coefcients (KSe,T,i,j, KSe,R,i,j, (8)
dx2 dy2 dz2 k k @x @t @y @t @z @t
KSe,Z,i,j) due to ploughing, the uncut chip thickness of hS,i,j(u) and the
width of cut of wS,i,j. The cutting coefcients can be determined where T; q; r; C p ; k are the temperature, the heat generation
using the mechanistic or the orthogonal oblique transformation rate per unit volume, the density, the thermal capacitance and the
techniques (Fig. 1). conductivity, respectively [9].
I. Lazoglu, B. Bugdayci / CIRP Annals - Manufacturing Technology 63 (2014) 113116 115
3. Simulations and model validations titanium salts. The IR camera has the spectral responsivity of 7
14 mm, interlace scanning property of 2:1 and minimum resolv-
All the simulations and validations were performed on able temperature difference of approximately 0.2 8C at 25 8C. The
Aerospace grade Aluminium alloy Al-7050. Firstly, the milling protective window prevents the objective from the chips. IR
cutting force model including the bottom edge effect was validated images were calibrated with thermocouple measurements at
with extensive number of cutting force measurements with rotary various temperatures in order to consider the effects of emissivity.
dynamometer measurements. The force simulations and the The cutting speeds in the IR temperature measurements were
experimental tests were performed with 16 mm diameter, two 40, 120 and 200 m/min. Two rake angles with 6 and 18 deg were
uted, 30 deg helix angle tungsten carbide tool at the spindle speed used in the experiments. The clearance angles of the tools were
of 4000 and 8000 rpm, at the feedrates of 0.1, 0.15 and 0.25 mm/ 6 deg. The cutting conditions for the IR temperature measurement
tooth. In the validation of the force model with the bottom edge experiments are given in Table 1.
effect, the maximum difference observed between the measured
and simulated force magnitudes were less than 10%. A typical Table 1
Cutting conditions for validations.
validation result for the milling force prediction including the
bottom edge effect is shown in Fig. 2. Test No.
1 2 3 4 5 6 7 8
500
Fx Simulated
Rake angle (8) 6 6 6 6 18 18 18 18
400 Fy Simulated
Feedrate (mm/rev) 0.05 0.1 0.15 0.2 0.05 0.1 0.15 0.2
Fz Simulated
Cutting Forces(N)
300 Fx Experimental
Fy Experimental In order to determine the average shear stress, average friction
200
Fz Experimental and shear angles (Table 2) for orthogonal to oblique force
100 transformation, cutting tests were performed. In these tests,
tangential and feed force components were measured at three
0
different cutting speeds and four feedrate values (Figs. 4 and 5).
-100
-200 Table 2
0 200 400 600 800 1000 1200 1400 1600 1800 2000
Calibration results for Al-7050.
Rotation angle(deg)
Tool rake Chip Shear Average Shear
Fig. 2. Simulated and experimental cutting forces for slot milling (spindle speed of angle (8) ratio angle (8) friction angle (8) stress (MPa)
8000 rpm, axial depth of cut of 2 mm, the feedrate of 0.25 mm/tooth).
6 0.57 31.5 33 287.1
18 0.55 32 40.5 266.8
As the asymptotic case of oblique machining, the orthogonal
machining tests with an infrared (IR) camera system were used
for thermal validations of the model. The IR tests were carried
out on Aerospace grade Al-7050 with WC tools as shown in
Fig. 3.
Fig. 4. Cutting forces measured during orthogonal cutting of Al-7050 for 68 rake
angle tungsten carbide tool.
The tool and the workpiece have the following properties; thermal
conductivity of 84 and 157 W/mK, specic heat capacity of 480 and
860 J/kg K, and density of 15,700 and 2800 kg/m3, respectively.
The simulated maximum temperatures and experimental infra-
red temperature measurements are shown in Fig. 6. The thermal
model shows good agreement with the experimental measurements.
Thermal simulations of the at end milling were also performed
Fig. 3. The infrared camera system integrated to the CNC machine tool for thermal
on Aerospace grade Al-7050 alloy with six tungsten carbide end
model validation tests. mills. All the six end mills were two uted, having 16 mm diameter
and 30 deg helix angle. The major difference between them was
the cobalt binding concentration (Table 3).
The infrared camera (Fig. 3) used in the experiments has an All of the tests were performed as slot milling at the spindle
uncooled focal plane array (FPA) detector. The IR camera has the speed of 8000 rpm and at 2 mm axial depth of cut. The milling
advantage of a ferroelectric phase transition in certain dielectric cutting forces were measured using the Kistler rotary dynamome-
materials and utilizing an array of pyroelectric elements in that ter. Simulations show that the temperature on the cutting tool at
plane, which is a ceramic material of barium, strontium and the maximum chip thickness can reach up to 421 8C (Fig. 7). The
116 I. Lazoglu, B. Bugdayci / CIRP Annals - Manufacturing Technology 63 (2014) 113116
Tool W C Co References
Weight Atomic Weight Atomic Weight Atomic
[1] Van Luttervelt CA, Childs THC, Jawahir IS, Klocke F, Venuvinod PK, Altintas Y,
A 79.8 30.4 9.9 57.4 10.4 12.3 Armarego E, Dornfeld D, Grabec I, Leopold J, Lindstrom B, Lucca D, Obikawa T,
B 83.1 37.0 7.3 49.5 9.7 13.5 Shirakashi. Sato H (1998) Present Situation and Future Trends in Modelling of
C 83.6 38.9 6.6 46.7 9.3 13.6 Machining Operations Progress Report of the CIRP Working Group Modelling
D 84.4 35.3 8.7 55.6 6.2 8.1 of Machining Operations. CIRP Annals Manufacturing Technology 47(2):
E 82.2 35.6 7.6 50.7 10.2 13.8 587626.
F 83.9 40.4 6.0 44.2 9.5 14.3 [2] Arrazola PJ, Ozel T, Umbrello D, Davies M, Jawahir IS (2013) Recent Advances in
Modelling of Metal Machining Processes. CIRP Annals Manufacturing Tech-
nology 62(2):695718.
[3] Jawahir IS, Brinksmeier E, MSaoubi R, Aspinwall DK, Outeiro JC, Meyer D,
Umbrello D, Jayal AD (2011) Surface Integrity in Material Removal Processes:
Recent Advances. CIRP Annals Manufacturing Technology 60(2):603626.
[4] Komanduri R, Hou ZB (2001) Thermal Modelling of the Metal Cutting Process
Part III: Temperature Rise Distribution Due to the Combined Effects of Shear
Plane Heat Source and the ToolChip Interface Frictional Heat Source. Inter-
national Journal of Mechanical Sciences 43:89107.
[5] Rech J, Arrazola PJ, Claudin C, Courbon C, Pusavec F, Kopac J (2013) Character-
isation of Friction and Heat Partition Coefcients at the Tool-Work Material
Interface in Cutting. CIRP Annals Manufacturing Technology 62(1):7982.
[6] Lazoglu I, Altintas Y (2002) Prediction of Tool and Chip Temperature in
Continuous and Interrupted Machining. International Journal of Machine Tools
& Manufacture 42:10111022.
[7] Ulutan D, Lazoglu I, Dinc C (2009) Three-Dimensional Temperature Predictions
in Machining Processes Using Finite Difference Method. Journal of Materials
Processing Technology 209:11111121.
[8] Dinc C, Lazoglu I, Serpenguzel A (2008) Analysis of Thermal Fields in Orthogo-
nal Machining with Infrared Imaging. Journal of Materials Processing Technology
198:147154.
[9] Lazoglu I, Islam C (2012) Modelling of 3D Temperature Fields for Oblique
Machining. CIRP Annals Manufacturing Technology 61:127130.
[10] Davies MA, Ueda T, MSaoubi R, Mullany B, Cooke AL (2007) On the Measure-
ment of Temperature in Material Removal Processes. CIRP Annals
Manufacturing Technology 56(2):581604.
[11] Ueda T, Hosokawa A, Oda K, Yamada K (2001) Temperature on Flank Face of
Fig. 7. Image of the worn tool and simulated tool temperature eld at the spindle Cutting Tool in High Speed Milling. CIRP Annals Manufacturing Technology
speed of 8000 rpm and the feedrate of 0.25 mm/tooth. 50(1):3740.