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TECHNICAL PAPERS

Modeling Cutting Temperatures for Turning Inserts With Various Tool Geometries and Materials

[+] Author and Article Information
Aloysius U. Anagonye

Staff Research Engineer, Enterprise Systems Lab., GM R&D and Planning, Mail Code 480-106-359, 30500 Mound Road, Warren, MI 48090-9055

David A. Stephenson

Manufacturing Engineering, GM Powertrain Group, Warren, MI 48090-9055

J. Manuf. Sci. Eng 124(3), 544-552 (Jul 11, 2002) (9 pages) doi:10.1115/1.1461838 History: Received January 01, 2000; Revised September 01, 2001; Online July 11, 2002
Copyright © 2002 by ASME
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References

Shaw, M. C., 1988, Temperatures in Cutting, ASME Winter Annual Meeting PED-Vol. 30, pp. 133–143.
Jaeger,  J. C., 1943, Moving Sources of Heat and the Temperatures at Sliding Contacts, Proc. R. Soc. Edinburgh, Sect. A: Math. Phys. Sci., 76, pp. 203–224.
Loewen,  E. G., and Shaw,  M. C., 1954, “On the Analysis of Cutting Tool Temperatures,” Trans. ASME, 76, pp. 217–231.
Tay,  A. O., Stevenson,  M. G., and de Vahl,  Davis, G., 1974, “Using the Finite Element Method to Determine Temperature Distributions in Orthogonal Machining,” Proc. Inst. Mech. Eng., 188, pp. 627–638.
Tay,  A. O., Stevenson,  M. G., de Vahl  Davis, G., and Oxley,  P. L. B., 1976, “A Numerical Method for Calculating Temperature Distribution in Machining from Force and Shear Angle Measurements,” Int. J. Mach. Tool Des. Res., 16, 335–349.
Muraka,  P. D., Barrow,  G., and Hinduja,  S., 1979, “Influence of the Process Variables on the Temperature Distribution in Orthogonal Machining using the Finite Element Method,” Int. J. Mech. Sci., 21, pp. 445–456.
Stevenson,  M. G., Wright,  P. K., and Chou,  J. G., 1983, “Further Developments in Applying the Finite Element Method to the Calculation of Temperature Distributions in Machining and Comparison with Experiments,” ASME J. Eng. Ind., 105, August.
Liu, C. R., Lin, Z. C., and Barash, M. M., 1984, Thermal and Mechanical Stresses in Workpiece During Machining, ASME Winter Meeting Proceedings on High Speed Machining, pp. 181–191.
Venuvinod,  P. K., and Lau,  W. S., 1986, “Estimation of Rake Temperatures in Free Obligue Cutting,” Int. J. Mach. Tool Des. Res., 26(1), pp. 1–14.
Stephenson,  D. A., 1991, “Assessment of Steady-State Metal Cutting Models Based on Simultaneous Infrared and Thermocople Data,” ASME J. Eng. Ind., 113, pp. 121–128, May.
Stephenson,  D. A., and Ali,  A., 1992, “A Tool Temperature in Interrupted Metal Cutting,” ASME J. Eng. Ind., 114, pp. 127–136, May.
Radulescu, R., and Kapoor, S. G., 1992, “An Analytical Model for Prediction of Tool Temperature Field During Continuous and Interrupted Cutting,” Material Issues in Machining and Physics of Machining Processes, Stevenson, R., and Stephenson, D. A., eds., pp. 147–165.
Young,  H. T., and Chou,  T. L., 1994, “Modelling of Tool/Chip Interface Temperature Distribution in Metal Cutting,” Int. J. Mech. Sci., 36(11), pp. 931–943.
Li,  X., Kopalinsky,  E. M., and Oxley,  P. L. B., 1995, “A Numerical Method for Determining Temperature Distributions in Machining with Coolant. Part 1: Modelling the Process, and Part 2: Calculation Method and Results,” Proc. Inst. Mech. Eng., 209, pp. 33–52; J. of Eng. Manufacture.
Stephenson, D. A., and Agapiou, J. S., 1996, Metal Cutting Theory and Practice, Chap. 7, Marcel Dekker, Inc., New York.
Jen, T-C., and Lavine, A. S., 1994, “Prediction of Tool Temperature in Cutting,” Proc. of 7th Int’l Symposium on Transport Phenomena in Manufacturing Processes, pp. 211–216.
Carslaw, H. S., and Jaeger, J. C., 1959, Conduction of Heat in Solids, Oxford University Press, Oxford, pp. 378–379.
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Trigger,  K. J., and Chao,  B. T., 1951, “An Analytical Evaluation of Metal Cutting Temperatures,” Trans. ASME, 73, pp. 57–68.
Chao,  B. T., and Trigger,  K. J., 1955, “Temperature Distribution at the Tool-Chip Interface in Metal Cutting,” Trans. ASME, 77, pp. 1107–1121.
Stephenson,  D. A., 1993, “Tool-work Thermocouple Temperature Measurements-Theory and Implementation Issues,” ASME J. Eng. Ind., 115, pp. 432–437.
Braiden, P. M., 1967, “The Calibration of Tool/Work Thermocouples,” Proc. 8th Int. Machine Tools Design and Research Conf., Birminghan, UK, pp. 653–665.
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Figures

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Sources of heat in metal cutting
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Geometry of a turning tool and its heat contact zone
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Idealization of a turning tool geometry as a semi-infinite rectangular corner
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Geometry of the tool insert
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The boundary conditions of the tool insert and holder
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The tool insert and holder finite element model
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Temperature distribution on an insert with nose radius (adiabatic boundary condition on “near” surfaces)
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Comparison of FEM results with data from Loewen and Shaw 3
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Effect of insert included angle—peak and average temperature rise on sharp inserts
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Effect of nose radius—peak and average temperature rise on inserts with 90 deg included angle
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Effect of different insert and tool holder materials—peak and average temperature rise on inserts with 90 deg included angle
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Peak temperature rise vs. insert included angle at various nose radii
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Average temperature rise vs. insert included angle at various nose radii
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Normalized temperature rise ratio vs. insert included angle for various nose radii inserts
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Schematics of the tool-work thermocouple experimental setup 21
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Thermoelectric calibration of tool-work EMF of uncoated WC-tool coupled to 1018 steel
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Shell element model of the insulating plates used in finite element analysis
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Thermoelectric EMF results for 35 deg and 80 deg inserts from thermocouple experiments

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