CUTTING TEMPERATURE MEASUREMENT IN HIGH-SPEED END MILLING

A computer aided measurement system is used to measure the cutting temperature directly in high-speed machining by natural thermocouples and standard thermocouples. In this system the tool/workpiece interface temperature is measured by the tool/workpiece natural thermocouple, while the temperature distribution on the workpiece surface and that of interior are measured by some standard thermocouples prearranged at proper positions. The system can be used to measure cutting temperature in the machining with the rotary cutting tools, such as vertical drill and end milling cutter. It is practically used for the research on high-speed milling with hardened steel.

Prediction of Wearing of Cutting Tools Using Real Time Machining Parameters and Temperature Using Rayleigh-Ham Method

Wear of cutting tools is a big concern for industrial manufacturers, because of their acquisition cost as well as the impact on the production lines when they are unavailable. Law of wear is very important in determining cutting tools lifespan, but most of the existing models don’t take into account the cutting temperature. In this work, the theoretical and experimental results of a dynamic study of metal machining against cutting temperature of a treated steel of grade S235JR with a high-speed steel tool are provided. This study is based on the analysis of two complementary approaches, an experimental approach with the measurement of the temperature and on the other hand, an approach using modeling. Based on unifactorial and multifactorial tests (speed of cut, feed, and depth of cut), this study allowed the highlighting of the influence of the cutting temperature on the machining time. To achieve this objective, two specific approaches have been selected. The first was to measure the temperature of the cutting tool and the second was to determine the wear law using Rayleigh-Ham dimensional analysis method. This study permitted the determination of a law that integrates the cutting temperature in the calculations of the lifespan of the tools during machining.

Dynamic Calibration of the Cutting Temperature Sensor of NiCr/NiSi Thin-film Thermocouple

In high-speed cutting, natural thermocouple, artificial thermocouple and infrared radiation temperature measurement are usually adopted for measuring cutting temperature, but these methods have difficulty in measuring transient temperature accurately of cutting area on account of low response speed and limited cutting condition. In this paper, NiCr/NiSi thin-film thermocouples（TFTCs） are fabricated according to temperature characteristic of cutting area in high-speed cutting by means of advanced twinned microwave electro cyclotron resonance（MW-ECR） plasma source enhanced radio frequency（RF） reaction non-balance magnetron sputtering technique, and can be used for transient cutting temperature measurement. The time constants of the TFTCs with different thermo-junction film width are measured at four kinds of sampling frequency by using Ultra-CFR short pulsed laser system that established. One-dimensional unsteady heat conduction model is constructed and the dynamic performance is analyzed theoretically. It can be seen from the analysis results that the NiCr/NiSi TFTCs are suitable for measuring transient temperature which varies quickly, the response speed of TFTCs can be obviously improved by reducing the thickness of thin-film, and the area of thermo-junction has little influence on dynamic response time. The dynamic calibration experiments are made on the constructed dynamic calibration system, and the experimental results confirm that sampling frequency should be larger than 50 kHz in dynamic measurement for stable response time, and the shortest response time is 0.042 ms. Measurement methods and devices of cutting heat and cutting temperature measurement are developed and improved by this research, which provide practical methods and instruments in monitoring cutting heat and cutting temperature for research and production in high-speed machining.

Theoretical modeling of cutting temperature in high-speed end milling process for die/mold machining

A parametric model of cutting temperature generated in end milling process is developed according to the thermal mechanism of end milling as an intermittent operation, which periodically repeats the cycle of heating under cutting and cooling under non-cutting. It shows that cutting speed and the tool-workpiece engagement condition are determinative for tool temperature in the operation. The suggested model was investigated by tests of AlTiN coated endmill machining hardened die steel JIS SKD61, where cutting temperature on the flank face of tool was measured with an optical fiber type radiation thermometer. Experimental results show that the tendency of cutting temperature to increase with cutting speed and engagement angle is intensified with the progressing tool wear.

Cutting Temperature and Tool Wear of Hard Turning Hardened Bearing Steel

A study was undertaken to investigate the performan ce of PCBN tool in the finish turning GCr15 bearing steel with different hardness between 30～64 HRC. The natural thermocouple was used to measure the cutting tem p erature, tool life and cutting temperature were investigated and compared. The m aterial can be heated by this instrument which using low voltage and high elec trical current, while PCBN can’t be heated by electrifying directly, so the ke ntanium layer coating over the PCBN is heated, so the PCBN is heated and its th ermoelectric property is got by this method. [TPP129,+60mm88mm,Y,PZ#] Fig.1 Effect of cutting depth and workpiec hardness on. the cutting temperatureThe objective was to determine the influence of the workpiece hardness on change s in cutting temperature and tool wear characterize. It can be found from Fig.1 that the cutting temperature show an increasing tendency with the improvement of workpiece hardness within the cutting speed scope when the workpiece hardness i s under HRC50. And on the other hand, it is found that the cutting temperature s how the downtrend with the improvement of workpiece hardness when the workpiece hardness is over HRC50. According to experimental results, the critical hard ness when turning hardened GCr15 bearing steel with PCBN tool is about HRC50. Th e wear causes of PCBN tool have been found out through taking photos on the micr o-shape of PCBN poly-laminate initial surface as well as face and flank of wea r tool and analysis on chemical elements. It is discovered that the PCBN tools a re not suitable for cutting the workpiece at nearly critical hardness, because n ear the critical hardness, PCBN wear at the highest speed. For researching the w ear rule of PCBN tool, the tool wear experiments have been carried on by using b earing steel GCr15 at hardness HRC40 and HRC60 with changing cutting speed. The indexes of tool life equations is gained under two kinds of conditions w hich are bigger than 0.6, so the effects of cutting speed on the PCBN tool are m uch less than that of carbide tool and ceramic tool.

Study on Cutting Force,Cutting Temperature and Machining Residual Stress in Precision Turning of Pure Iron with Different Grain Sizes

Pure iron is one of the difficult-to-machine materials due to its large chip deformation,adhesion,work-hardening,and built-up edges formation during machining.This leads to a large workpiece deformation and challenge to meet the required technical indicators.Therefore,under varying the grain size of pure iron,the influence of cutting speed,feed,and depth of cut on the cutting force,heat generation,and machining residual stresses were explored in the turning process to improve the machinability without compromising the mechanical properties of the material.The experimental findings have depicted that the influence of grain size on cutting force in the precision turning process is not apparent.However,the cutting temperature and residual stress of machining fine-grain iron were much smaller than the coarse grain at all levels of cutting parameters.

Performance evaluation of minimum quantity lubrication by vege-table oil in terms of cutting force,cutting zone temperature,tool wear,job dimension and surface finish in turning AISI-1060 steel

In all machining processes, tool wear is a natural phenomenon and it leads to tool failure. The growing demands for high productivity of machining need use of high cutting velocity and feed rate. Such machining inherently produces high cutting temperature, which not only reduces tool life but also impairs the product quality. Metal cutting fluid changes the performance of machining operations because of their lubrication, cooling and chip flushing functions, but the use of cutting fluid has become more problematic in terms of both employee health and environmental pollution. The minimization of cutting fluid also leads to economical benefits by way of saving lubricant costs and workpiece/tool/machine cleaning cycle time. The concept of minimum quantity lubrication (MQL) has been suggested since a decade ago as a means of addressing the issues of environmental intru- siveness and occupational hazards associated with the airborne cutting fluid particles on factory shop floors. This paper deals with experimental investigation on the role of MQL by vegetable oil on cutting temperature, tool wear, surface roughness and dimen- sional deviation in turning AISI-1060 steel at industrial speed-feed combinations by uncoated carbide insert. The encouraging results include significant reduction in tool wear rate, dimensional inaccuracy and surface roughness by MQL mainly through reduction in the cutting zone temperature and favorable change in the chip-tool and work-tool interaction.

Numerical Simulation for Three-Dimensional (3D) Unsteady State Temperature Field in Circumferential Laser Oxygen Cutting of Pipes

A 3D unsteady state numerical model of heat transfer in the circumferential laser oxygen cutting of pipes wasdeveloped. In order to minimize the computing time required for solving the finite difference equations as much aspossible, the alternating direction implicit (ADI) method was adopted. Based on the characteristics of the pipe cuttingprocess, the periodic boundary condition was applied to calculate the temperature distribution in the θ direction andthe self-adaptive grid technology was also used. The mathematical model takes account of the temperature-dependentthermal properties of the pipe. The calculated kerfs width and the heat-affected zone (HAZ) were compared withthe experimental results.

Finite Element Analysis and OADs Optimization of the Temperature in the Plane-strain Orthogonal Metal Cutting Process

In order to analyze the influences of the different tool’s shape and surface conditions (such as different coated and material) and their interaction on the cutting temperature, a coupled thermo-mechanical finite element analysis (FEA) model of plane-strain orthogonal metal cutting process is constructed, and 16 simulation cases with 16 different types of tools, which cover 4 rake angles, -10°, 0°, 10°, 20°, and 4 friction coefficient values, 0, 0.1, 0.2, 0.3 in the same cutting condition (cutting depth and cutting speed) have been performed. Finally the simulation results are analyzed according to the variance analysis method (VAM) of orthogonal array designs (OADs), the relationships between the rake angle, tool-workpiece interface’s friction coefficient and their interact effect to the maximum temperature value and the temperature field of the chip are obtained. This result has some instructive meaning to analyze the causes of the cutting temperature and to control the maximum temperature value and the overall temperature field in the metal cutting process.

Study on the Cutting Temperature of the Textured Tool by 3D FEA Simulation

Temperature plays an important role in the life of cutting tools.However,it is sometimes difficult to observe instantaneously because of limited data acquisition,especially for the textured tool.In this paper,the performance of microgroove textured cutting tools for three-dimensional(3D)oblique dry turning of AISI 1045 steel was studied by finite element simulation.The effects of width,depth and spacing of strip micro-texture on cutting temperature and the effect of cutting speed on cutting temperature of strip microtexture tool were studied.The results show that the maximum temperature of the tool and the tip temperature first increase and then decrease with the increase of micro-texture width.When the micro-texture depth increases,the maximum temperature and the tool tip temperature decrease first and then increase.The highest temperature and tip temperature of the tool gradually increase with the increase of micro-texture spacing.The highest temperature and tip temperature of the tool increase with the increase of cutting speed,feed speed and cutting depth.In addition,the effective mechanism of micro-texture parameter for the temperature was proposed.It provides profound guidance for optimizing the microstructure parameters and cutting process of cutting tools according to cutting temperature in this study.It also provides an effective and practical method for the design,innovation and development of microtextured tools.

CUTTING TEMPERATURE OF CBN TOOLS WHEN MACHINING STEEL OF MEDIUM HARDNESS

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Temperature distribution in the tool-chip-workpiece system during the orthogonal cutting process

The temperature distribution in the tool, chip and workpiece was studied during the orthogonal cuttingprocess Under several different cutting conditions. The temperature distribution is calculated by the finite differencemethod. and the variation of the material properties with temperature was taken was taken into account The results obtained arecoincident with both previous published results and experimental measurements.

Parameter estimation of cutting tool temperature nonlinear model using PSO algorithm

In cutting tool temperature experiment, a large number of related data could be available. In order to define the relationship among the experiment data, the nonlinear regressive curve of cutting tool temperature must be constructed based on the data. This paper proposes the Particle Swarm Optimization (PSO) algorithm for estimating the parameters such a curve. The PSO algorithm is an evolutional method based on a very simple concept. Comparison of PSO results with those of GA and LS methods showed that the PSO algorithm is more effective for estimating the parameters of the above curve.

CUTTING TEMPERATURE OF TEMPERING BEARING STEEL GCr15 CUT BY PCBN CUTTER

A thermoelectric curve of GCr15 BN500 is acquired by rapid label way. The study on measuring the cutting temperature with PCBN cutter is done and the calculation formula is achieved. A series of experiments about cutting temperature are made for different hardness tempering bearing steel at the same time. The rule that cutting temperature increases with increasing of the cutting speed, feed, back engagement of the cutting edge is gained. It is known that the cutting temperature is highest under the condition that back engagement of the cutting edge a p≥2.5 mm and the machined material hardness equals to 50HRC.

STUDY ON THE CUTTING TEMPERATURE IN GEAR HOBBING

According to work tool thermocouple principle,the equipment for measuring hobbing temperature is developed.The changing character of cutting temperature in gear hobbing,the relation between cutting conditions and hobbing temperature,and the influence of cutting conditions on hobbing temperature are discussed by means of experiments.All these have provided the reference standards for the equitably selecting cutting conditions and geometrical parameter of hob,prolonging the life of gear hobs,and predicting processes of gear hobbing.

Prospect of HDR geothermal energy exploitation in Yangbajing,Tibet,China,and experimental investigation of granite under high temperature and high pressure

Hot dry rock （HDR） geothermal energy, almost inexhaustible green energy, was first put forward in the 1970s. The development and testing of HDR geothermal energy are well reported in USA, Japan, UK, France and other countries or regions. In this paper, the geological characters of Yangbajing basin were first analyzed, including the continental dynamic environments to form HDR geothermal fields in Tibet, the tectonic characteristics of south slope of Nyainqentanglha and Dangxiong-Yangbajing basin, and the in-situ stresses based on the investigations conducted, and then the site-specific mining scheme of HDR geothermal resources was proposed. For the potential development of HDR geothermal energy, a series of experiments were conducted on large-scale granite samples, 200 mm in diameter and 400 mm in length, at high temperature and high triaxial pressure for cutting fragmentation and borehole stability. For the borehole stability test, a hole of 40 mm in diameter and 400 mm in length was aforehand drilled in the prepared intact granite sample. The results indicate that the cutting velocity obviously increases with temperature when bit pressure is over a certain value, while the unit rock-breaking energy consumption decreases and the rock-breaking efficiency increases with temperature at the triaxial pressure of 100 MPa. The critical temperature and pressure that can result in intensive damage to granite are 400-500℃ and 100-125 MPa, respectively.

CT Image-based Analysis on the Defect of Polypropylene Fiber Reinforced High-Strength Concrete at High Temperatures

With the application of X-ray computed tomography（CT） technology of C80 high-strength concrete with polypropylene fiber at elevated temperatures, the microscopic damage evolution process observation and image building could be obtained, based on the statistics theory and numerical analysis of the combination of concrete internal defects extension and evolution regularity of microscopic structure. The expermental results show that the defect rate has changed at different temperatures and can determine the concrete degradation threshold temperatures. Also, data analysis can help to establish the evolution equation between the defect rate and the effect of temperature damage, and identify that the addition of polypropylene fibers in the high strength concrete at high temperature can improve cracking resistance.

Development of 2D Temperature and Concentration Measurement Method Using Tunable Diode Laser Absorption Spectroscopy

Exhaust gas temperature is an important factor in NOx, THC and PM emissions of engines. Especially 2D temperature and concentration distribution plays an important role for the engine efficiency. A thermocouple is intrinsically a point temperature measurement method and noncontact 2D temperature distribution cannot be attained by thermocouples. Recently, as a measurement technique with high sensitivity and high response, laser diagnostics has been developed and applied to the actual engine combustions. With these engineering developments, transient phenomena such as start-ups and load changes in engines have been gradually elucidated in various conditions. In this study, the theoretical and experimental research has been conducted in order to develop the noncontact and fast response 2D temperature and concentration distribution measurement method. The method is based on a Computed Tomography （CT） method using absorption spectra of water vapor at 1388 nm. It has been demonstrated that the method has been successfully applied to engine exhausts to measure 2D temperature distributions.

Diagnosis of Temperature Field by Ultrasonic CT-In case of limited projection angle

超声波CT作为一种热测量方法 ,具有不接触、对温度场不干扰的优点。本文发展一种新的超声波CT再现方法 ,用于解决受限透视角度所产生的信息量不足的问题。新的超声波CT再现算法建立在逆矩阵变换的基础上 ,它不同于通常的采用SL过滤器的所谓FBPCT再现方式。论文中描述了三种CT迭代再现算法 ,用计算机模拟结果和三维温度场测量实验数据验证了再现算法的可靠性。同时根据计算和实验结果 ,建议在受限的透视角度情况下 。

Theoretical Studies on the SAW Properties of LGS at High-Temperature in Optimal Cuts

Surface acoustic wave (SAW) devices play a significant role in signal processing, frequency control and sensing applications. In general, they cannot operate at elevated temperature. The new crystal of langasite provides possibility for surface acoustic wave devices applied at high temperature. This paper studies the SAW properties of single and doubly rotated cuts of LGS at high temperature. The calculated SAW properties of LGS are analyzed in space with aid of contour plots, and two promising SAW orientation regions at high temperature are presented. For some typical cuts and propagating directions within the two optimal regions, their SAW characteristics vs temperature are discussed. Based on the experimental evidence in some literatures, the reliability of calculated results is verified.