Research Papers

A Thermal Model to Predict Tool Temperature in Machining of Ti–6Al–4V Alloy With an Atomization-Based Cutting Fluid Spray System

[+] Author and Article Information
Asif Tanveer, Deepak Marla

Department of Mechanical Science
and Engineering,
University of Illinois at Urbana-Champaign,
Urbana, IL 61801

Shiv G. Kapoor

Department of Mechanical Science
and Engineering,
University of Illinois at Urbana-Champaign,
Urbana, IL 61801
e-mail: sgkapoor@illinois.edu

1Corresponding author.

Manuscript received August 20, 2016; final manuscript received February 14, 2017; published online April 18, 2017. Assoc. Editor: Radu Pavel.

J. Manuf. Sci. Eng 139(7), 071016 (Apr 18, 2017) (9 pages) Paper No: MANU-16-1456; doi: 10.1115/1.4036123 History: Received August 20, 2016; Revised February 14, 2017

In this study, a heat transfer model of machining of Ti–6Al–4V under the application of atomization-based cutting fluid (ACF) spray coolant is developed to predict the temperature of the cutting tool. Owing to high tool temperature involved in machining of Ti–6Al–4V, the model considers film boiling as the major heat transfer phenomenon. In addition, the design parameters of the spray for effective cooling during machining are derived based on droplet–surface interaction model. Machining experiments are conducted and the temperatures are recorded using the inserted thermocouple technique. The experimental data are compared with the model predictions. The temperature field obtained is comparable to the experimental results, confirming that the model predicts tool temperature during machining with ACF spray cooling satisfactorily.

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Fig. 1

Schematic of ACF spray system setup

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Fig. 2

We versus v at different droplet diameters

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Fig. 3

Km versus v at different droplet diameters

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Fig. 4

Droplet velocity profiles for 12.5 and 30 μm-size droplets along the spray distance

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Fig. 5

Film boiling phenomenon: (a) initial film formation when cold, (b) nucleate boiling after 8 min, and (c) film boiling after 15 min

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Fig. 6

Flowchart of modeling approach

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Fig. 7

Geometry of the tool with boundary conditions

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Fig. 8

Schematic showing the film boiling of droplet

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Fig. 9

Schematic of droplet just before impact and at maximum spreading

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Fig. 14

Temperature profile for different cutting conditions

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Fig. 13

Comparison between numerical and experimental results

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Fig. 12

Predicted temperature contour plot of the tool for 0.2 mm/rev feed, 80 m/min speed

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Fig. 11

Position of slots in the WC insert at 0.15 mm and 0.35 mm from flank edge

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Fig. 10

Experimental setup for the temperature measurement




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