CHAPTER # 2

Thermal Aspects in Machining

 Topics to be covered:
• Sources of heat generation in machining and its effects

• Temperature Measurement techniques in machining

• Types of cutting fluids

• Functions of cutting fluid

• Characteristics of cutting fluid

• Application of cutting fluids

• Economics of Metal Cutting Operations

 Heat generation:
• Temperature is the main limitation in the selection of
process parameters.

• Heat generation depends on the rate of metal cutting,

cutting speed, specific heat and thermal conductivity of the
work piece and tool material.

• Distributed between work piece, tool, chip and

surrounding.
• The amount of dissipated by surroundings is very small and
can be neglected.
• The heat distributed in metal cutting operation is
approximately 70:15:15 between chips, tool and work
piece.
Heat distribution :
 Source of heat generation in machining:
• In the elastic deformation, the energy required for the
operation is stored in the material as strain energy and no
heat is generated.

• However, in case of plastic deformation, most of the

energy used is converted into heat.

• There are three sources/regions for heat generation in

metal cutting:-
1. Primary deformation zone
2. Tool-chip interface zone or Secondary deformation
zone
3. Tool work piece interface zone
Source of heat generation in machining: contd…
 Source of heat generation in machining: contd…

• Heat generated in primary zone is mainly due to plastic

deformation and viscous dissipation.

• In secondary zone, heat is generated due to chip distortion.

Metal layer inside the bend and adjacent to tool tip is
stretched while layer away from the tip is contracted.
Hence, there is distortion of grains in the chip which leads
to internal friction between heated chip and tool face.

• In Work-tool interface zone, heat is generated due to

friction by rubbing action between portion of tool flank and
work piece.
 Effect of various factors:
Material of tool and work:
• Higher hardness and tensile strength of material required
more cutting force and hence higher heat generated.

Tool Geometry:
• The rake angle has complex influence on the cutting
temperature.
• If rack angle increase in positive direction both cutting force
and amount of heat generated are decreased. Negative
rack angle causes deformations.
• As the nose radius increase, volume of tool point is
increases and it promotes more heat conduction.
• Large cross section area of tool shank leads more heat
conduction and it reduces cutting temperature.
 Effect of various factors:
contd…
Cutting Parameter:
• As cutting speed increases, friction will increases and it
raise the temperature of cutting zone.
• Cutting temperature is also increase with increase in feed
and depth of cut.

Cutting Fluid:
• Cutting fluid is not only reduces friction but also absorb and
carry away heat from work, chips and tool.
 Effect on cutting tool:
• Plastic deformation of cutting edges if tool material is not
enough hard

• Thermal fracturing of cutting edges

• Formation of built up edge

• Rapid tool wear

 Effect on workpiece:
• Dimensional inaccuracy

• Rapid corrosion due to surface damage by oxidation

• Burning

• Micro-cracks at the surface

 Measurement of chip-tool interface temperature:
• There are number of methods for measuring the chip tool
interface temperature as…
• Tool-work thermocouple,
• Radiation pyrometers,
• Embedded thermocouples,
• Temperature sensitive paints etc.
 Measurement of chip-tool interface temp. contd…

• Tool and work material as two elements of thermocouple.

• The hot junction is contact area at the cutting edge.
• Cold part of tool forms cold junction.

[Tool-work thermocouple]
 Measurement of chip-tool interface temp. contd…

• The thermoelectric emf [electromotive force] generated

between the tool and work piece during metal cutting is
measured using sensitive milli-voltmeter.

• These emf readings are converted in terms of temperature.

 Cutting fluid:
• Cutting fluid are those liquid and gases which are applied to
cutting zone to facilitate cutting operation by removing
heat.
 Functions of cutting fluid:
• To keep tool cool and prevent it from being heated.

• To reduce friction and power consumption, hence increase the

tool life.

• To decrease adhesion between chip and tool.

• To cool workpiece to prevent expansion.

• To wash away chips and keep cutting region free mainly during
deep hole drilling, Hacksawing, milling and grinding.

• To protect the finished surface from corrosion.

• To Improve Machinability.
 Characteristics of cutting fluid:
contd…
• High specific heat and thermal conductivity.

• Ability of spreading and wetting.

• High lubricity without gumming and foaming.

• Chemically stable and non corrosive.

• Non toxic, odorless and colorless.

• It should have high film boiling point and high flash point.

• High resistance to bacterial growth.

• Easily available with low cost.

 Method of application of cutting fluid:
• The effectiveness and cutting fluid significantly depends on
how it is applied in respect of flow rate and direction of
application.

Cutting fluid generally employed by following ways:

1. Flood Cooling:
• It is most common method.
• Flow rate is 10 to 20 liter/min for single point cutting tool.
• Up to 230 liter/min for multiple tooth cutters.
• Multiple nozzles should be used.
 Method of application of cutting fluid: contd…

2. Mist Cooling:

• Small jet equipment is used to disperse water base fluid as

fine droplets in carrier.

• As carrier generally air at pressure 70 to 550 kPa.

• Mist cooling provides high velocity fluids and better

visibility.

• Limitation due to requirement of venting.

 Method of application of cutting fluid: contd…

3. High Pressure refrigerated Cooling:

• It is very effective in removing heat at high rates.

• Generally used in CNC.

• Fluid directed at relief angle at pressure of 35,000 kPa.

• In this system continuous filtering of fluid is essential to

eliminate damage of workpiece due to impact of any
contaminants that may be present in cooling system.
 Recommended cutting fluids:
Workpiece Material Cutting Fluid
Steels  For HSS tools: Soluble oil for (1:20)
 For Carbide tools: Thinner solution oil
Grey C I  Air blast for cooling and flushing chips
 Soluble oil for high speed machining
Al and Al alloy  Preferably dry
 Light and oily soluble oil
 Kerosene for stringent cuts

Copper and its alloy  Water based fluids

 Oil for High grade copper
SS  High performance soluble oil
Ceramics  Dry condition mostly
 Light neat oil in case of fine finishing
High Speed grinding  Soluble oil ( 1:50 to 1:100)
 Low viscosity neat oil
Effect of cutting speed on various cost of
machining:
Effect of cutting speed on various time and
production rate: