Evaluating Cutting Fluid Effects on Cylinder Boring Surface Errors by Inverse Heat Transfer and Finite Element Methods

[+] Author and Article Information
Y. Zheng, H. Li, W. W. Olson, J. W. Sutherland

Dept. of Mechanical Engineering— Engineering Mechanics, Michigan Technological University, 1400 Townsend Drive, Houghton, MI 49931

J. Manuf. Sci. Eng 122(3), 377-383 (Sep 01, 1999) (7 pages) doi:10.1115/1.1285865 History: Received June 01, 1997; Revised September 01, 1999
Copyright © 2000 by ASME
Your Session has timed out. Please sign back in to continue.


Subramani,  G., Kapoor,  S. G., and DeVor,  R. E., 1993, “A Model for the Prediction of Bore Cylindricity During Machining,” ASME J. Eng. Ind., 115, pp. 15–22.
Zhang, G. M., and Kapoor, S. G., 1985, “Dynamic Modeling and Analysis of the Boring Machine System,” Proc. of the ASME Symposium on Sensors and Controls for Manufacturing, PED-18 , pp. 11–20.
Subramani, G., Suvada, R., Kapoor, S. G., DeVor, R. E., and Meingast, W., 1987, “A Model for the Prediction of Force System for Cylinder Boring Process,” Proc. of the 15th North Amer. Manf. Res. Conf., pp. 439–446.
Sutherland, J. W., Subramani, G., Kuhl, M. J., DeVor, R. E., and Kapoor, S. G., 1988, “An Investigation into the Effect of Tool and Cut Geometry on Cutting Force System Prediction Models,” Proc. of the 16th North Amer. Manf. Res. Conf., pp. 264–272.
Childs,  T. H. C., Maekawa,  K., and Maulik,  P., 1998, “Effects of Coolant on Temperature Distribution in Metal Cutting,” Mater. Sci. Technol., 4, pp. 1006–1019.
Incropera, F. P., and DeWitt, D. P., 1990, Introduction to Heat Transfer, 2nd ed., Wiley, New York.
Rapier,  A. C., 1954, “A Theoretical Investigation of the Temperature Distribution in the Metal Cutting Process,” Br. J. Appl. Phys., 5, November, pp. 400–405.
Weiner,  J. H., 1955, “Shear Plane Temperature Distribution in Orthogonal Cutting,” Trans. ASME, 77, No. 8, pp. 1331–41.
Subramani,  G., Whitmore,  M. C., Kapoor,  S. G., and DeVor,  R. E., 1991, “Temperature Distribution in a Hollow Cylindrical Workpiece During Machining: Theoretical Model and Experimental Results,” ASME J. Eng. Ind., 113, No. 4, pp. 373–380.
Yen,  D. W., and Wright,  P. K., 1986, “Remote Temperature Sensing Technique for Estimating the Cutting Interface Temperature Distribution,” ASME J. Eng. Ind., 108, pp. 252–263.
Chow,  J. G., and Wright,  P. K., 1988, “On-line Estimation of Tool/Chip Interface Temperature for a Turning Operation,” ASME J. Eng. Ind., 110, pp. 56–64.
Watts, R. G., and McClure, E. R., 1968, “Thermal Expansion of Workpiece During Turning,” ASME Paper, No. 68-WA/Prod-24.
Watts,  R. G., 1969, “Temperature Distributions in Solid and Hollow Cylinders Due to a Moving Circumferential Ring Heat Source,” J. Heat Transfer, 91, pp. 465–470.
Ichimiya,  R., and Kawahara,  H., 1971, “Investigation of Thermal Expansion in Machining Operations,” Bull. JSME, 14, No. 78, pp. 1363–1371.
Stephenson,  D., 1991, “An Inverse Method for Investigating Deformation Zone Temperatures in Metal Cutting,” ASME J. Eng. Ind., 113, pp. 129–136.
Stephenson,  D., Barone,  M., and Dargush,  G., 1995, “Thermal Expansion of the Workpiece in Turning,” ASME J. Eng. Ind., 117, pp. 542–550.
Kakade, N. N. and Chow, J. G., 1989, “Computer Simulation of Bore Distortions for Engine Boring Operation,” Proc. of the Symp. on Collected Papers in Heat Transfer, Winter Annual Meeting, San Francisco, CA, Vol. 123, pp. 259–265.
Ozisik, M. N., 1968, Boundary Value Problems of Heat Conduction, International Textbook Company.
Cozzens, D. A., 1995, A Study of Cutting Fluids and Workpiece Surface Error in the Boring of Cast Aluminum Alloys, M. S. Thesis, Michigan Technological University.
Jacobus,  K. J., DeVor,  R. E., and Kapoor,  S. G., 1999, “Part Warpage Model Based on Machining-Induced Residual Stress,” Trans. NAMRI/SME, 27, pp. 75–80.
Fuh,  K. H., Ching-Fu,  Wu, 1995, “A Residual-Stress Model for the Milling of Aluminum Alloy (2014-T6),” J. Mater. Process. Technol., 51, pp. 87–105.
Ozisik, M. N., 1980, Heat Conduction, Wiley, New York.


Grahic Jump Location
Picture of the experimental setup
Grahic Jump Location
Schematic of a cylinder bore with mounted thermocouples
Grahic Jump Location
Predicted and measured temperatures for tests # 1 & # 8
Grahic Jump Location
Cylinder bore illustrating heat loss terms
Grahic Jump Location
Deformed cylinder at t=10 seconds due to the cutting forces, test #1
Grahic Jump Location
“Force-induced” surface error vs. axial position in the bore for test #1
Grahic Jump Location
Predicted temperature distribution in the bore at different times
Grahic Jump Location
Deformed bore due to the thermal deformation at t=10 second
Grahic Jump Location
Surface error (due to thermal deformation) versus axial position based on FEM model
Grahic Jump Location
Measured surface error versus predicted (elastic+thermal) surface error




Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In