Thermal Aspects of Machining

Thermal Aspects

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 Temperature
 Approximately 98% of the energy in machining
(plastic deformation) is converted into heat.
Thermal Aspects of Machining

the remaining energy (about 2%) is retained

as elastic energy in the chip.
☼ temperatures to be very high at the tool-chip
☼ produce hot chips that pose safety hazards
to the machine operator.
☼ temperature rise in the tools is maximum for
tough materials with low specific heat.

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 CUTTING TEMPERATURES

• Conversion of energy into heat

• Influences tool wear
• Affects the quality of the product
Thermal Aspects of Machining
Distribution of Heat Generated

Vs Vc
10-20%
Tool

80-90% 2-3%
V

Work

 Large part of the heat goes away with the chip.

 Temp proportional to friction on the chip interface.
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 Apportionment of heat amongst
Thermal Aspects of Machining
chip, tool and workpiece

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 Effects of High Cutting Temperature
On cutting tool
Thermal Aspects of Machining

☺ Rapid tool wear, which reduces tool life

☺ Plastic deformation of the cutting edges

if the tool is not enough hot-hard.

☺ Thermal flaking and fracturing of cutting

edges due to thermal shocks

☺ Biult-up-Edge formation.

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 Effects of High Cutting Temperature
On the job
Thermal Aspects of Machining

͏ Dimensional inaccuracies of job due to

thermal distortion, expansion-contraction
during and after machining
͏ Surface damage by oxidation, rapid
corrosion and burning, etc.
͏ Induction of thermal residual stresses and
micro cracks on machined surface and
sub-surface

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 Average Shear Zone Temperature
Let
Q = the rate of heat generation during
Thermal Aspects of Machining

machining
= the power consumption
Qc = rate of heat generation at the contact
between chip and tool
Qs = rate of heat generation in the primary
deformation (shear) zone

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Thermal Aspects of Machining Average Shear Zone Temperature

J = mechanical equivalent of heat of the chip /

work material

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Thermal Aspects of Machining Average Shear Zone Temperature

generally
A varies from 0.95 to 1.0 and
q1 from 0.7 to 0.9 in machining like turning.
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Thermal Aspects of Machining Average Shear Zone Temperature

+ Room Temperature

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 Experimental Methods
Most frequently used technique is the
tool-chip thermocouple
Thermal Aspects of Machining

Gotwein’s Method

 Using this method, Ken Trigger determined the

speed-temperature relationship to be of the
form:
T=KVm
where T = measured tool-chip interface temp.
V = cutting speed,
K = thermal diffusivity of the work material (cm2/s)

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 Thermal Aspects of Machining Principle of Thermocouple

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Thermal Aspects of Machining Tool-Work Thermocouple

Fig.: Tool-Work Thermocouple (Gottwein’s Method)

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Thermal Aspects of Machining Tool-work Thermocouple Calibration

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Thermal Aspects of Machining Tool-work Thermocouple Calibration

Y = 10.288 X
R2 = 0.9988

Fig. Tool-work thermocouple calibration curve

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 Thermal Aspects of Machining Tool-work Thermocouple

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Thermal Aspects of Machining Inserted Thermocouple Technique

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 Thermal Aspects of Machining Embedded Thermocouple

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 Radiation Method
According to Planck’s law, the power
radiated per unit area per unit wavelength
Thermal Aspects of Machining

Wλ depends on the absolute temperature T

and wavelength λ

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 Micro-Hardness Method
850
Thermal Aspects of Machining

Hardness, HV

HSS

HCS

200 400 600 800

Temperature, 0C

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 Dimensional Analysis
Kronenberg in 1949
let
Thermal Aspects of Machining

where

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 Thermal Aspects of Machining Dimensional Analysis

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Thermal Aspects of Machining Dimensional Analysis

Mc+d+e=0 (i)
L  a + 2b - c + d - e = 0 (ii)

T  - a - 2c - 3d - 2e = 0 (iii)
θ -d-e=1 (iv)

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 Dimensional Analysis

assume, d = - 2
Thermal Aspects of Machining

 e = 1 (from iv)
 c = 1 (from i)
 a = 2 (from iii)
 b = 1 (from ii)

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 Average Chip-Tool interface Temperature
Analytical method derived by Nathan Cook
from dimensional analysis using exptl data
Thermal Aspects of Machining

for various work materials

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 Thermal Aspects of Machining Temperature in Turning

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 Control of Cutting Temperatures

 Proper selection of material and geometry

Thermal Aspects of Machining

of the cutting tool

 Optimum selection of cutting speed and
feed combination without sacrificing MRR
 Proper selection and application of cutting
fluid
 Application of special technique, if required
and feasible

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 Thermal Aspects of Machining

Pb.:
Exercise problems

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 Exercise problems
(b): For the same conditions, calculate the mean
shear zone temperature rise ΔT, when the metal
Thermal Aspects of Machining

has a specific cutting energy of 2.8 GN/m2;

μ = 1.0; rc = 0.2 and 10% of the shear zone
heat is conducted into the workpiece. Assume,
for the work material, that ρ = 7,200 kg/m3 and
Cp = 500 J/kgK
(c): What would be the value of ΔT, if the cutting
speed were doubled and the proportion of
shear-zone heat conducted into the workpiece
remained the same.

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 References

 Metal Cutting Principles, M.C. Shaw, Oxford Publishers

Thermal Aspects of Machining

 Fundamentals of Modern Manufacturing: Materials,

Processes and Systems, by Mikell P Groover, John Wiley
 Manufacturing Technology, by P.N. Rao, TMH
 Machining & Machine Tools , by AB Chattopadhyay, Wiley
 Fundamentals of Machining and Machine Tools,
by G. Boothroyd, Int. McGraw Hill
 Measurement Systems, by JE Doebelin, Int. McGraw Hill

A. Venu Gopal 31