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Thermal Aspects of Metal Cutting Process

This document discusses thermal aspects of metal cutting processes. It describes how heat is generated during cutting and how temperature is distributed in the workpiece and chip. Various experimental methods for measuring cutting temperature are outlined, including thermocouples, color-changing indicators, and embedded sensors. The effects of high cutting temperatures on tool wear and workpiece quality are also summarized. Maintaining an optimal temperature is important for process performance and tool life. Cutting fluids can help control temperature through cooling and lubricating properties.

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188 views14 pages

Thermal Aspects of Metal Cutting Process

This document discusses thermal aspects of metal cutting processes. It describes how heat is generated during cutting and how temperature is distributed in the workpiece and chip. Various experimental methods for measuring cutting temperature are outlined, including thermocouples, color-changing indicators, and embedded sensors. The effects of high cutting temperatures on tool wear and workpiece quality are also summarized. Maintaining an optimal temperature is important for process performance and tool life. Cutting fluids can help control temperature through cooling and lubricating properties.

Uploaded by

CORONA EVENT
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Thermal aspects in metal

cutting process
LEARNING OBJECTIVES

 Heat Generation in metal cutting


 Temperature distribution in work and chip in orthogonal cutting
 Measurement of temperature in metal cutting
 Control of Cutting Temperature
 Cutting Fluids in Machining
Why do we want to know the cutting temperature ?
 To know the machining performance
 To design and select the cutting tool
 To find out thermal stresses

 Critical strain at ductile fracture


 The temperature distribution in the work piece, in this instance the chip zone, as seen in typical experimental
study , is given in Figure . As point X in the material moves towards the cutting tool, it approaches and passes
through the primary deformation zone, and is heated till it leaves the zone, being carried away within the chip,
However point Y passes through both deformation zones and continues to get heated till leaves the region of
secondary deformation. It is then cooled as the heat is conducted into the body of chip, and eventually the chip
achieves a uniform temperature throughout. The maximum temperature thus occurs along the tool face some
distance from the cutting edge. The point Z , that remains in the workpiece , is heated as it passes below the tool
cutting edge, by conduction of heat from the primary deformation zone. Some heat is removed from the secondary
deformation zone by conduction into the body of the tool.
EFFECTS OF THE HIGH CUTTING
TEMPERATURE ON TOOL AND WORK

 Rapid tool wear , which reduces tool life


 Cutting edges plastically deform and tool may loose its hot hardness
 Thermal flaking and fracturing of cutting edges may take place due to thermal shock
 Built up edge formation
 Dimension inaccuracy of work duet to thermal distortion and expansion and
contraction during and after machining
 Surface damage by oxidation, rapid corrosion, burning etc.
 Tensile residual stresses and microcracks at the surface and sub surfaces.
DETERMINATION OF CUTTING
TEMPERATURE

Cutting temperature can be determined by two ways

 Analytically – using mathematical models (equations) if available or can be


developed. This method is simple, quick and inexpensive but less accurate and
precise.
 Experimentally – this method is more accurate, precise and reliable.
The temperatures which are of major interests are :

 Average shear zone temperature


 Average /Maximum temperature at the chip tool interface
 Temperature at the work –tool interface ( tool flanks)
 Average cutting temperature
Experimental methods of determination of cutting
temperature and measurement of cutting tool :
 Calorimetric method – quite simple and low cost but inaccurate and gives only
grand average value
 De colouring agent – some paint or tape, which change in colour with variation of
temperature, is pasted on the tool or job near the cutting point; the as such colour
of the chip (steels) may also often indicate cutting temperature
 Tool-work thermocouple – simple and inexpensive but gives only average or
maximum value
 Moving thermocouple technique
 Embedded thermocouple technique
 Compound Rake Tool Method
Tool work thermocouple technique
 Both the tool and materials have to be electrically and thermally conductive for this
technique.
 The difference in temperature between the hot and relatively cold junctions produces
a proportional voltage which is detected or measured in terms of volts by a millivolt
meter.
Moving thermocouple technique
 This method is useful for study of the gradual rise in temperature of continuous chips
at low and moderate cutting velocities.
Embedded thermocouple technique
 Useful for milling and surface grinding processes.
 The temperature is maximum when the thermocouple bead comes very near to the
milling cutter.
Compound Rake Tool Method
 Developed to measure the chip-tool interface temperature along the rake surface by
thermocouple technique.
Essential Properties of Cutting Fluids:
1. For cooling:
✓ High specific heat, thermal conductivity and film coefficient of heat transfer.
✓ Spreading and wetting ability.
2. For lubrication:
✓ High lubricity without gumming and foaming
✓ Wetting and spreading
✓ High film boiling point
✓ Friction reduction at extreme pressure and temperature
3. Chemical stability
4. Less volatility and high flash point
5. High resistance to bacterial growth
6. Odorless and preferably colorless
7. Non-toxicity in both liquid and gaseous stages
8. Easy availability at low cost.
THANK YOU…

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