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Technical Brief

On Cutting Temperature Measurement During Titanium Machining With an Atomization-Based Cutting Fluid Spray System

[+] Author and Article Information
Alexander C. Hoyne

Department of Mechanical Science and Engineering,
University of Illinois at Urbana–Champaign,
1206 W. Green Street,
Urbana, IL 61801
e-mail: ahoyne2@gmail.com

Chandra Nath

Post Doctorate Research Associate
Department of Mechanical Science and Engineering,
University of Illinois at Urbana–Champaign,
1206 W. Green Street,
Urbana, IL 61801
e-mail: nathc2@asme.org

Shiv G. Kapoor

Professor
Department of Mechanical Science and Engineering,
University of Illinois at Urbana–Champaign,
1206 W. Green Street,
Urbana, IL 61801
e-mail: sgkapoor@illinois.edu

1Present address: Mechanical Engineer, John Deere, Waterloo, IA 50704.

2Present address: Postdoctoral Fellow, George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA 30332.

3Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received July 2, 2014; final manuscript received September 29, 2014; published online December 12, 2014. Assoc. Editor: Y. B. Guo.

J. Manuf. Sci. Eng 137(2), 024502 (Apr 01, 2015) (6 pages) Paper No: MANU-14-1353; doi: 10.1115/1.4028898 History: Received July 02, 2014; Revised September 29, 2014; Online December 12, 2014

The poor thermal conductivity and low elongation-to-break ratio of titanium lead to the development of extreme temperatures (in excess of 550 °C) localized in the tool–chip interface during machining of its alloys. At such temperature level, titanium becomes highly reactive with most tool materials resulting in accelerated tool wear. The atomization-based cutting fluid (ACF) spray system has recently been demonstrated to improve tool life in titanium machining due to good cutting fluid penetration causing the temperature to be reduced in the cutting zone. In this study, the cutting temperatures are measured both by inserting thermocouples at various locations of the tool–chip interface and the tool–work thermocouple technique. Cutting temperatures for dry machining and machining with flood cooling are also characterized for comparison with the ACF spray system temperature data. Findings reveal that the ACF spray system more effectively reduces cutting temperatures over flood cooling and dry conditions. The tool–chip friction coefficient indicates that the fluid film created by the ACF spray system also actively penetrates the tool–chip interface to enhance lubrication during titanium machining.

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References

Figures

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Fig. 1

Inserted thermocouple measurement setup

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Fig. 2

Inserted thermocouple with copper guard

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Fig. 3

Tool–work thermocouple measurement setup

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Fig. 4

Tool–work thermocouple calibration curve

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Fig. 5

(a) Schematic of the ACF spray system [21] and (b) ACF spray parameters in turning setup [2]

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Fig. 6

Photograph of the setup with the ACF spray system in the CNC lathe

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Fig. 7

Tool–work thermocouple temperature measurements

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Fig. 8

Tool–chip contact length measurements

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Fig. 9

Inserted thermocouple temperature measurements

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Fig. 10

Chip lifting–falling cycle during titanium machining: (a) Chip lifting allows thin film to penetrate (less fluid excretes) and (b) chip falling causes more fluid excretion from the interface [21]

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Fig. 11

Friction coefficient development over machining for flood cooling and the ACF spray system

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