Experimental Study and Finite Element Modeling of Workpiece Temperature in Finish Cylinder Boring

[+] Author and Article Information
Lei Chen

Department of Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109

Bruce Tai

Department of Mechanical Engineering, Texas A&M University, College Station, TX 77843

Juhchin A. Yang

Virtual Manufacturing Section, Ford Motor Company, Livonia, MI 48150

Albert J. Shih

Department of Mechanical Engineering, and Department of Biomedical Engineering, University of Michigan, Ann Arbor, MI, 48109

1Corresponding author.

ASME doi:10.1115/1.4037554 History: Received March 08, 2017; Revised July 24, 2017


Thermal expansion of the workpiece during cylinder boring process is one of the sources causing the bore cylindricity error. To study thermal expansion induced bore distortion, detailed workpiece temperature distribution in cylinder boring is required. Four finite element models, namely the advection model, surface heat model, heat carrier model and ring heat model, were developed to predict the workpiece temperature in cylinder boring. Cylinder boring experiments were conducted utilizing the tool-foil and embedded thermocouple experimental approaches to measure the workpiece temperature, predict the temperature distribution using the inverse heat transfer method, and evaluate the capability of the four models in terms of accuracy and efficiency. Results showed an accurate global temperature prediction for all models and a good correlation with the embedded thermocouple experimental measurements. Good correlation was also obtained between the tool-foil thermocouple measurement of machined surface temperature and model predictions. Advantages and disadvantages as well as applicable scenarios of each model were discussed. For studying detailed cylinder boring workpiece temperature, it is suggested to use the ring heat model to estimate the moving heat flux and the heat carrier model for local workpiece temperature calculation.

Copyright (c) 2017 by ASME
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