Research Papers

Estimation of Milling Tool Temperature Considering Coolant and Wear

[+] Author and Article Information
Hsin-Yu Kuo

Mechanical Engineering,  University of Michigan, 2350 Hayward Street, Ann Arbor, MI 48105hsinyu@umich.edu

Kevin Meyer

GE Aviation, 1 Neumann Way, MD E74, Cincinnati, OH 45215-1988kevin.meyer@ge.com

Roger Lindle

GE Aviation, 1 Neumann Way, MD E74, Cincinnati, OH 45215-1988roger.lindle@ge.com

Jun Ni

Mechanical Engineering,  University of Michigan, 2350 Hayward Street, Ann Arbor, MI 48105junni@umich.edu

J. Manuf. Sci. Eng 134(3), 031002 (Apr 25, 2012) (8 pages) doi:10.1115/1.4005799 History: Received November 17, 2010; Revised October 19, 2011; Published April 24, 2012; Online April 25, 2012

This paper presents a novel technique to estimate the temperature distribution of a milling tool during machining. In this study, heat generation during the machining process is estimated using cutting forces. We consider the heat to be time-dependent heat flux into the tool. In the proposed model, we discretize each rake face on a mill into several elements; each experiences time-dependent heat flux. Second, we calculate the time-dependent heat flux as several constant heat input starts at different time. Finally, we sum the temperature rise from each heat flux to obtain the overall temperature change. A similar concept is applied on the flank surface, where the flank wear area is modeled as an additional heat generation zone. Experimental results are presented to validate the developed model.

Copyright © 2012 by American Society of Mechanical Engineers
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Figure 1

Elemental cutting edge on the flutes of ball-end mill

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Figure 2

(a) Nozzle position; (b) the view perpendicular to coolant axis

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Figure 3

Discretization and heat flux on the tool rake and flank surfaces of each ECT

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Figure 4

Uniform heat flux between two points on the surface of a semi-infinite plane

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Figure 5

A time-dependent heat flux and the superposition of constant heat flux

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Figure 6

Modeling result for 500 rpm, 0.23 m/min feed rate, at 1.27 mm depth of cut ECT

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Figure 7

Temperature distribution in the tool

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Figure 8

Comparison of different ECTs on the cutting edge

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Figure 9

Comparison of different flank wear VBs

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Figure 10

The transient temperature of an ECT in a full revolution

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Figure 11

Basic elements of the tool-foil thermocouple system

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Figure 12

Thermoelectric calibration for the copper and tungsten carbide (WC) combination

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Figure 13

Experimental results for copper 3.3 mm from tool center

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Figure 14

Validation results for different ECTs at the end-of-cut half

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Figure 15

Validation results for different ECTs at the begin-of-cut half

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Figure 16

Validation results for different ECTs with flank wear

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Figure 17

Validation results for different cutting conditions




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