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Research Papers

Tool–Chip Interface Temperature Measurement in Interrupted and Continuous Oblique Cutting

[+] Author and Article Information
Sinan Kesriklioglu, Justin D. Morrow

Department of Mechanical Engineering,
University of Wisconsin-Madison,
Madison, WI 53706

Frank E. Pfefferkorn

Department of Mechanical Engineering,
University of Wisconsin-Madison,
Madison, WI 53706
e-mail: frank.pfefferkorn@wisc.edu

1Corresponding author.

Manuscript received July 19, 2017; final manuscript received September 27, 2017; published online March 7, 2018. Editor: Y. Lawrence Yao.

J. Manuf. Sci. Eng 140(5), 051013 (Mar 07, 2018) (6 pages) Paper No: MANU-17-1460; doi: 10.1115/1.4038140 History: Received July 19, 2017; Revised September 27, 2017

The objective of this work is to fabricate instrumented cutting tools with embedded thermocouples to accurately measure the tool–chip interface temperature in interrupted and continuous turning. Thin-film thermocouples were sputtered directly onto the flat rake face of a commercially available tungsten carbide cutting insert using micromachined stencils and the measurement junction was coated with a protective layer to obtain temperature data 1.3 μm below the tool–chip interface. Oblique interrupted cutting tests on AISI 12L14 steel were performed to observe the influence of varying cutting speeds and cooling intervals on tool–chip interface temperature. An additional cutting experiment was conducted to monitor the interface temperature change between interrupted and continuous cuts.

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References

Juvinall, R. C. , and Marshek, K. M. , 2006, Fundamentals of Machine Component Design, Wiley, New York.
Trigger, K. J. , and Chao, B. T. , 1950, An Analytical Evaluation of Metal-Cutting Temperatures, ASME, New York.
Lazoglu, I. , and Altintas, Y. , 2002, “ Prediction of Tool and Chip Temperature in Continuous and Interrupted Machining,” Int. J. Mach. Tools Manuf., 42(9), pp. 1011–1022. [CrossRef]
Stephenson, D. A. , and Ali, A. , 1992, “ Tool Temperatures in Interrupted Metal Cutting,” J. Eng. Ind., 114(2), pp. 127–136.
Garcia-Gonzalez, J. C. , Moscoso-Kingsley, W. , and Madhavan, V. , 2016, “ Tool Rake Face Temperature Distribution When Machining Ti6Al4V and Inconel 718,” Procedia Manuf., 5, pp. 1369–1381. [CrossRef]
Basti, A. , Obikawa, T. , and Shinozuka, J. , 2007, “ Tools With Built-In Thin Film Thermocouple Sensors for Monitoring Cutting Temperature,” Int. J. Mach. Tools Manuf., 47(5), pp. 793–798. [CrossRef]
Werschmoeller, D. , Ehmann, K. , and Li, X. , 2011, “ Tool Embedded Thin Film Microsensors for Monitoring Thermal Phenomena at Tool-Workpiece Interface During Machining,” ASME J. Manuf. Sci. Eng., 133(2), p. 021007. [CrossRef]
Sugita, N. , Ishii, K. , Furusho, T. , Harada, K. , and Mitsuishi, M. , 2015, “ Cutting Temperature Measurement by a Micro-Sensor Array Integrated on the Rake Face of a Cutting Tool,” CIRP Ann. Manuf. Technol., 64(1), pp. 77–78. [CrossRef]

Figures

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Fig. 1

Mask fabrication for thin-film thermocouple sputtering

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Fig. 2

Holder for the cutting insert and masks

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Fig. 4

Fabricated thermocouple before protective coating

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Fig. 5

Instrumented cutting insert

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Fig. 6

Cross section of the coating layers

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Fig. 7

Scheme of the workpiece with (a) five and (b) two interruptions

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Fig. 11

Rake face of the instrumented cutting insert after all experiments

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Fig. 10

(a) Tool chip interface temperature during interrupted and continuous cutting with two ribs at a cutting speed of 200 m/min and (b) temperature change in two revolutions

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Fig. 9

(a) Tool chip interface temperature during interrupted cutting with five ribs at a cutting speed of 60 m/min and (b) temperature during two revolutions

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Fig. 8

(a) Tool chip interface temperature during interrupted cutting with five ribs at a cutting speed of 200 m/min and (b) temperature change in two revolutions

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