Research Papers

An Inverse Heat Transfer Method for Determining Workpiece Temperature in Minimum Quantity Lubrication Deep Hole Drilling

[+] Author and Article Information
Bruce L. Tai, David A. Stephenson, Albert J. Shih

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

J. Manuf. Sci. Eng 134(2), 021006 (Apr 04, 2012) (8 pages) doi:10.1115/1.4005794 History: Received September 01, 2010; Revised November 23, 2011; Published March 30, 2012; Online April 04, 2012

This study investigates the workpiece temperature in minimum quantity lubrication (MQL) deep hole drilling. An inverse heat transfer method is developed to estimate the spatial and temporal change of heat flux on the drilled hole wall surfaces based on the workpiece temperature measured using embedded thermocouples and analyzed using the finite element method. The inverse method is validated experimentally in both dry and MQL deep-hole drilling conditions and the results show good agreement with the experimental temperature measurements. This study demonstrates that the heat generated on the hole wall surface is significant in deep hole drilling. In the example of deep hole drilling of ductile iron, the level of thermal power applied on the hole wall surface is about the same as that on the hole bottom surface when a 10 mm drill reached a depth of 120 mm.

Copyright © 2012 by American Society of Mechanical Engineers
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Figure 1

HWS, HBS and the 2D axisymmetric finite element mesh

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Figure 2

Workpiece temperature Ti by the superposition of Tbi and Twi

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Figure 3

The fitting process of hb using temperature response to different factor k

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Figure 4

Segments and temperature input points (thermocouple locations) along the hole depth in the model

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Figure 5

The control points to determine the heat flux spatial distribution on HWS

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Figure 6

The sequence to activate the control points: (a) stage 1 when x2 ≥ x4 > 0 and (b) stage 2 when x3 ≥ x4 > x2

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Figure 7

Experimental setup on Cross Hüller machine

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Figure 8

Measured temperature and calculated Tb at five input points under MQL condition

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Figure 9

Comparison of inverse solution and calculated heat flux from each ECT

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Figure 10

Sensitivity tensor (a) Iij 11 calculated by transient FEA and (b) Iij 1q (q = 10) calculated by shifting the response results of Iij 11

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Figure 11

Results of inverse solution on hw

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Figure 12

Torque data from an MQL deep hole drilling test

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Figure 13

Temperature validation at points A and B using Approach #1

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Figure 14

Heat flux change on HWS by applying inverse solutions from (a) five input points and (b) three input points

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Figure 15

Temperature validation at points A and B using Approach #2

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Figure 16

Temperature distribution of the workpiece under MQL condition by considering heat from (a) HBS, (b) HBS and HWS (Approach #1 or #2 with five input points)

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Figure 17

The comparison of thermal power varying with drilling depth on HBS and HWS



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