A Thermo-mechanical Model of Dry Orthogonal Cutting and its Experimental Validation through Embedded Micro-scale Thin Film Thermocouple Arrays in PCBN Tooling

Linwen Li*, Bin Li, Kornel F. Ehmann, Xiaochun Li

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

26 Scopus citations

Abstract

Cutting temperature and its distribution in the cutting zone are a critical factor that significantly affects tool life and degrades part accuracy during metal removal operations. However, issues surrounding their modeling and experimental validation in the immediate cutting zone still remain an unresolved issue. A major impediment is the unavailability of adequate temperature measurement methods with sufficient temporal and spatial resolution to measure actual temperatures and validate predictive models. In this paper, a model for the dry orthogonal cutting process with thermo-mechanical coupling effects, i.e., interactions between the stress state, strain rates and the temperature softening of material in the plastic deformation zone, is proposed to predict cutting temperature distribution in the cutting zone. The feasibility and prediction accuracy of the model is verified by experimental measurements through Thin Film Thermocouple (TFTC) arrays embedded at the immediate vicinity of the cutting zone into Polycrystalline Cubic Boron Nitride (PCBN) tooling. The experimental verification is performed under hard turning conditions. It has been shown that the predictions of the proposed model are in very close agreement with the experimentally measured results including the cutting forces, chip thickness and cutting temperature distributions on the rake and flank faces in the cutting zone. Furthermore, the modeling results have also provided an essential understanding on the stress distributions at the tool/chip and work/tool interfaces as well as of the nature of the chip flow velocity along the rake face of the cutting tool.

Original languageEnglish (US)
Pages (from-to)70-87
Number of pages18
JournalInternational Journal of Machine Tools and Manufacture
Volume70
DOIs
StatePublished - Jul 2013

Keywords

  • Cutting temperature distribution
  • Cutting temperature measurements
  • Cutting temperature modeling
  • Micro thin film thermocouples
  • PCBN hard turning
  • Stress distributions

ASJC Scopus subject areas

  • Mechanical Engineering
  • Industrial and Manufacturing Engineering

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