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Research Papers

Experimental Investigation of Hard Turning Mechanisms by PCBN Tooling Embedded Micro Thin Film Thermocouples

[+] Author and Article Information
Linwen Li

Department of Mechanical Engineering,
Northwestern University,
2145 Sheridan Road,
Evanston, IL 60208-3111;
State Key Laboratory of Digital
Manufacturing Equipment and Technology,
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
C611 Room, East Building,
1037 Luoyu Road, Wuhan,
Hubei 430074,
China e-mail: linwen.lee@gmail.com

Bin Li

State Key Laboratory of Digital
Manufacturing Equipment and Technology,
School of Mechanical Science and Engineering,
Huazhong University of Science and Technology,
C608 Room, East Building,
1037 Luoyu Road, Wuhan, Hubei 430074, China
e-mail: libin999@mail.hust.edu.cn

Xiaochun Li

Department of Mechanical Engineering,
University of Wisconsin–Madison,
1035 Mechanical Engineering Building,
1513 University Avenue,
Madison, WI 53706-1572
e-mail: xcli@engr.wisc.edu

Kornel F. Ehmann

Department of Mechanical Engineering,
Northwestern University,
2145 Sheridan Road,
Evanston, IL 60208-3111
e-mail: k-ehmann@northwestern.edu

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the Journal of Manufacturing Science and Engineering. Manuscript received June 25, 2012; final manuscript received January 24, 2013; published online July 17, 2013. Assoc. Editor: Robert Gao.

J. Manuf. Sci. Eng 135(4), 041012 (Jul 17, 2013) (12 pages) Paper No: MANU-12-1187; doi: 10.1115/1.4023722 History: Received June 25, 2012; Revised January 24, 2013

Temperature-distribution measurements in cutting tools during the machining process are extremely difficult and remain an unresolved problem. In this paper, cutting temperature distributions were measured by thin film thermocouples (TFTCs) embedded into polycrystalline cubic boron nitride (PCBN) cutting inserts in the immediate vicinity of the tool-chip interface. The embedded TFTC array provides temperature measurements with a degree of spatial resolution (100 μm) and dynamic response (150 ns) that is not possible with currently employed methods due to the micro-scale junction size of the TFTCs. Using these measurements during hard turning, steady-state, dynamic, as well as chip morphology and formation process analyses were performed based on the cutting temperature and cutting force variations in the cutting zone. It has been shown that the temperature changes in the cutting zone depend on the shearing band location in the chip and the thermal transfer rate from the heat generation zone to the cutting tool. Furthermore, it became evident that the material flow stress and the shearing bands greatly affect not only the chip formation morphology but also the cutting temperature field distributions in the cutting zone of the cutting insert.

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References

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Figures

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Fig. 1

PCBN insert and thin film thermocouple array layout

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Fig. 2

Block diagram of experimental system

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Fig. 3

Photograph of experimental setup: (a) orthogonal cutting test arrangement, (b) side view of specimen, and (c) enlarged sensing unit and insert clamp

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Fig. 4

Example of cutting force and tool temperature evolution versus time at vc = 250 m/min

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Fig. 5.

Evolution of average measured cutting temperatures for each embedded TFTC versus cutting speed during the stabilized cutting stage

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Fig. 6

Cutting temperature distributions as a function of embedding location and cutting speed: (a) schematic of the temperature measurements in the cutting zone, (b) temperature distribution on the rake face, and (c) temperature distribution on the flank face

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Fig. 7

Comparison of FFT analysis results for recorded signals; vc = 250 m/min

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Fig. 8

Comparison of wavelet analysis results for vibration and cutting force; vc = 250 m/min

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Fig. 9

Energy percentage distributions for vibration, cutting force, and temperature in the frequency domain; vc = 250 m/min

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Fig. 10

Shifts in chip segmentation frequency as a function of cutting speed

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Fig. 11

Energy percentage evolutions as a function of frequency and cutting speed

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Fig. 12

Change of chip morphology. Columns: (1) the overall chip style, (2) chip type, and (3) chip micromorphology. Rows: (a) vc = 250 m/min, (b) vc = 400 m/min, (c) vc = 550 m/min, (d) vc = 700 m/min, (e) vc = 850 m/min, and (f) vc = 1000 m/min.

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Fig. 13

Correlation between instantaneous cutting force, cutting temperature, and chip segment formation; vc = 250 m/min

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