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Since the heat flow is balanced (+ = +), thus For the same conductivity, we have:
𝜕𝑇 𝜕 2 𝑇 𝜕 2 𝑇 𝑞ሶ 𝜌𝑐 𝜕𝑇
−𝑘𝐴 + 𝑞𝐴𝑑𝑥
ሶ 2𝐷: + + = (𝑓)
𝜕𝑥 𝜕𝑥 2 𝜕𝑦 2 𝑘 𝑘 𝜕𝜏
𝜕𝑇 𝜕𝑇 𝜕 𝜕𝑇
= 𝜌𝑐𝐴 𝑑𝑥 − 𝐴 𝑘 + 𝑘 𝑑𝑥
𝜕𝜏 𝜕𝑥 𝜕𝑥 𝜕𝑥 𝜕 2 𝑇 𝜕 2 𝑇 𝜕 2 𝑇 𝑞ሶ 𝜌𝑐 𝜕𝑇
3𝐷: + + + = (𝑔)
𝜕𝑥 2 𝜕𝑦 2 𝜕𝑧 2 𝑘 𝑘 𝜕𝜏
The above 1D equation can be simplified to
𝜕 𝜕𝑇 𝜕𝑇 In the metal cutting operation, there is no heat generated
𝑘 + 𝑞ሶ = 𝜌𝑐 (𝑏)
𝜕𝑥 𝜕𝑥 𝜕𝜏 within the element (𝑞=0).
ሶ Thus these equations become:
or
𝜕 2 𝑇 𝜕 2 𝑇 𝜌𝑐 𝜕𝑇
𝜕2𝑇 𝜕𝑇 2𝐷: + − =0 (ℎ)
𝑘 + 𝑞ሶ = 𝜌𝑐 (𝑐) 𝜕𝑥 2 𝜕𝑦 2 𝑘 𝜕𝜏
𝜕𝑥 2 𝜕𝜏
for the same thermal conductivity k. 𝜕 2 𝑇 𝜕 2 𝑇 𝜕 2 𝑇 𝜌𝑐 𝜕𝑇
3𝐷: + + − =0 (𝑖)
𝜕𝑥 2 𝜕𝑦 2 𝜕𝑧 2 𝑘 𝜕𝜏
Similarly, 2D and 3D cases can also be obtained:
𝜕 𝜕𝑇 𝜕 𝜕𝑇 𝜕𝑇 In the textbook, the 2D case is considered:
2𝐷: 𝑘 + 𝑘 + 𝑞ሶ = 𝜌𝑐 (𝑑)
𝜕𝑥 𝜕𝑥 𝜕𝑦 𝜕𝑦 𝜕𝜏
𝜕 𝜕𝑇 𝜕 𝜕𝑇 𝜕 𝜕𝑇 𝜕 2 𝜃 𝜕 2 𝜃 𝑅 𝜕𝜃
3𝐷: 𝑘 + 𝑘 + 𝑘 + − =0 (3.3)
𝜕𝑥 𝜕𝑥 𝜕𝑦 𝜕𝑦 𝜕𝑧 𝜕𝑧 𝜕𝑦 2 𝜕𝑥 2 𝑎𝑐 𝜕𝑥
𝜕𝑇
+𝑞ሶ = 𝜌𝑐 (𝑒) 3-5
𝜕𝜏
Chapter 3: Temperatures in
ME4870: Machining – J Lieh
Metal Cutting
Compare Eq. (3.3.) and Eq. (h), and substitute R = It is useful to consider the solution of this equation for a
ρcv𝑎𝑐 /k, we get: 1-D case, and this 1-D case is depicted in Figure 3.4.
𝑅 𝜌𝑐 ρcv𝑎𝑐 ρcv Velocity of Heat source P
= = = (𝑗) material v Unit
𝑎𝑐 𝑘 𝑎𝑐 𝑘 𝑘 thickness
where a
𝑘 = thermal conductivity
𝑐 = specific heat capacity 𝜃 = 𝜃𝑠
ρ = density
𝑣 = cutting velocity 𝜃 = 𝜃𝑠 𝑒 𝑅𝑥/𝑎 Temperature
𝑎𝑐 = undeformed chip thickness distribution
𝛷𝑐
3.3 TEMPERATURE DISTRIBUTION IN 680
METAL CUTTING
Figure 3.5 shows an experimentally determined 𝑎0 = 0.036 in.
(0.91 mm)
temperature distribution during orthogonal metal cutting.
670 730
This is a typical temperature distribution for orthogonal
chip formulation.
750
Point x is moving toward the cutting tool, approaches and Temperatures
o
passes through the primary deformation zone, it is heated in C
until leaves the zone and is carried away within the chip. 𝑥
𝛷𝑡
Point y passes both deformation zones, and it is heated
until it has left the region of secondary deformation zone. 𝑦
𝑧
It is then cooled as the heat is conducted into the chip
𝑎𝑐 = 0.024 in. 𝛷𝑤
which achieves a uniform temperature throughout. (0.61 mm)
Thus the maximum temperature occurs along the tool
FIGURE 3.5 Temperature distribution in workpiece and chip
face some distance from the cutting edge.
during orthogonal cutting (obtained from an infrared
Point z remaining in the workpiece is heated by the photograph) for free-cutting mild steel where the cutting speed
conduction of heat from the primary deformation zone. is 75 ft/min (0.38 m/s) , the width of cut is 0.25 in. (6.35 mm),
Some heat is conducted from the secondary deformation the working nmal rake is 30 degrees, and the workpiece
temperature is 611 OC.
zone into the body of the tool. 3-7
Chapter 3: Temperatures in
ME4870: Machining – J Lieh
Metal Cutting
The idealized model is assumed that the primary This theoretical relationship between 𝛤 and R tan 𝜙 is
deformation zone could be regarded as compared with experimental data un Figure 3.7, where it
a plane heat source of uniform strength is seen that the theory has slightly underestimated results
no heat was lost from the free surfaces of the at high values of R tan 𝜙 (i.e., at high speeds and feeds).
workpiece and ship
the thermal properties of the work material were 0.7
constant and independent of temperature Weiner2 (theoretical)
Nakayama4 (experimental)
0.6 Brass (𝜙=10o)
Steel (𝜙=20o)
It is assumed that no heat was conducted in the material 0.5 Steel (𝜙=30o)
in the direction of it its motion (x), the Eq. (3.3) can be 0.4
rewritten as
𝛤
0.3
𝜕 2 𝜃 𝑅 𝜕𝜃
− =0 (3.6) 0.2
𝜕𝑦 2 𝑎 𝜕𝑥
0.1
Eq. (3.6) can be solved within the stipulated boundary 0
0.3 1.0 10 30
conditions for the workpiece. R tan 𝜙
An equation expressing 𝛤 (the proportion of 𝑃𝑠 FIGURE 3.7 Effect of Rtan 𝜙 on division of shear-zone heat
conducted into the workpiece) is a unique function of between chip and workpiece, where 𝛤 = the proportion of
Rtan 𝜙 (where 𝜙 is the shear angle). shear-zone heat conducted into the workpiece, R = thermal
number, and 𝜙 = the shear angle.
3-9
Chapter 3: Temperatures in
ME4870: Machining – J Lieh
Metal Cutting
𝜃𝑚 = temperature rise of the material passing through The average temperature rise of the chip resulting from
the secondary deformation zone the secondary deformation zone 𝜃𝑓 (frictional heat
source) is given by
𝜃𝑠 = temperature rise of the material passing through
the primary deformation zone, given by Eq. (3.5) 𝑃𝑓
𝜃𝑓 = (3.9)
𝜃0 = initial working temperature 𝜌𝑐𝑣𝑎𝑐 𝑎𝑤
where
The solution to Eq. (3.6) obtained by Rapier is 𝜌 = density
𝑐 = specific heat capacity
𝜃𝑚 𝑅 𝑣 = cutting velocity
= 1.13 (3.8)
𝜃𝑓 𝑙0 𝑎𝑐 = undeformed chip thickness
𝑎𝑤 = width of cut
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Chapter 3: Temperatures in
ME4870: Machining – J Lieh
Metal Cutting
14
The boundary condition shown in Figure 3.8 are thought
to approximate more closely the real conditions.
12
Shear 𝜕𝜃
plane =0
𝜕𝑦 10
𝑦 𝑅
=∞
Chip 𝑙0
8
𝑎0 𝜃𝑠
𝜃𝑚
𝜃𝑓
𝑥 6
𝑤0 𝑎0
4
𝑙0 𝑎0 𝜕𝜃
=0
𝜕𝑦
Uniformly 2
distributed (𝜃𝑚 + 𝜃𝑠 )
heat source
0
FIGURE 3.8 Revised boundary condition for chip. 0 0.1 0.2 0.3 0.4 0.5 0.6
𝑤0
FIGURE 3.9 Effect of width of secondary deformation zone on
An analysis based on the revised model yielded results
chip temperature, where R = thermal number, 𝑙0 𝑎0 = chip-tool
that agreed with experimental data. These results, shown contact length, 𝑤0 𝑎0 = width of secondary deformation zone,
in Figure 3.9, indicate the effect of variations on the 𝜃𝑚 = maximum temperature rise in the chip, and 𝜃𝑓 = mean
width of uniformly distributed heat source. temperature rise in the chip. 3-11
Chapter 3: Temperatures in
ME4870: Machining – J Lieh
Metal Cutting
Since 𝛾𝑛𝑒 = 0 and from Eq. (2.35) & Eq. (2.36), we get 𝑎𝑐
or 𝑟𝑐 = = tan 𝜙 = 0.3
𝑎0
𝐹𝑡 = 𝐹𝑟 sin 𝛽 − 𝛾𝑛𝑒 = 𝐹𝑟 sin 𝛽
𝐹𝑓 = 𝐹𝑟 sin 𝛽 Thus, 𝑅 tan 𝜙 = 41.45 0.3 = 12.43
This results in 𝐹𝑓 = 𝐹𝑡 .
Use Figure 3.7 to find 𝛤 (with 𝑅 tan 𝜙 = 12.43).
Thus
𝑃𝑓 = 𝐹𝑓 𝑣𝑟𝑐 = 667 2 0.3 = 400 J/s (22.8 Btu/min)
0.7
Weiner2 (theoretical)
The heat generation from shearing is given by Eq. (3.2): Nakayama4 (experimental)
0.6 Brass (𝜙=10o)
𝑃𝑠 = 𝑃𝑚 − 𝑃𝑓 = 1380 J/s (78.5 Btu/min) Steel (𝜙=20o)
0.5 Steel (𝜙=30o)
For metal cutting, these parameters are known 0.4
ρ = 7200 kg/m3 -- density of steel
𝛤
0.3
c = 502 J/kgK -- specific heat capacity
k = 43.6 J/smk -- thermal conductivity 0.2
The average temperature rise θ𝑠 of the material passing through From Figure 3.9,
the primary deformation zone is given by Eq. (3.5)
14
[1 – 𝛤] 𝑃𝑠 [1 – 0.1] (1380)
θ𝑠 = = = 275 o𝐶
𝜌𝑐𝑣𝑎𝑐 𝑎𝑤 (7200)(502)(2)( 0.25 )( 2.5 )
1000 1000 12
𝜃𝑚
𝜃𝑓
1000 1000
To obtain the ratio 𝜃𝑚 /𝜃𝑓 from Figure 3.9, it is necessary to 6
estimate the values of w0 and R/l0.
4
From Figure 3.8 and given value, the length of contact between
chip and tool 𝑙𝑓 = 𝑙0 𝑎0 = 0.75 mm, thus
2
𝑙𝑓 𝑙𝑓 𝑟𝑐 (0.75)(0.3)
𝑙0 = = = = 0.9
𝑎0 𝑎𝑐 0.25
0
𝑅 41.45 0 0.1 0.2 0.3 0.4 0.5 0.6
Therefore the ratio = = 46.06 𝑤0
𝑙0 0.9
We get
For mild steel under unlubricated cutting, it is assumed the
𝜃𝑚
width of the secondary deformation divided by the chip = 4.2
thickness 𝑤0 = 0.2. 𝜃𝑓 3-14
Chapter 3: Temperatures in
ME4870: Machining – J Lieh
Metal Cutting
Thus temperature rise of the material passing through the 3.3.4 Effect of Cutting Speed on Temperature
secondary deformation zone (θ𝑚 ) is
If the tool forces and the cutting ratio are constants, for the
θ𝑚 = 4.2 θ𝑓 = 4.2 88.5 = 372 o𝐶 conditions used in the preceding example, the relationships
between temperatures and v shown in Figure 3.11 are obtained.
Assume the material is at the room temperature, i.e.,
θ0 = 22 oC 700
600
The maximum temperature along the tool rake face is given by 𝜃𝑚 + 𝜃𝑠
𝜃𝑠
Temperature, oC
Eq. (3.7), i.e., 500
𝜃𝑚𝑎𝑥 = 𝜃𝑚 + 𝜃𝑠 + 𝜃0 = 372 + 275 + 22 = 669 o𝐶 400
300
Note: 200
In the calculations, the thermal properties of the material are 100
assumed to be constant and independent of temperature.
0
0.3 0.4 0.5 0.6 0.8 1.0 2.0 3.0 4.0 5.0
With many engineering materials, however, the specific heat Cutting speed v, m/s
capacity (c) and the thermal conductivity (k) vary
considerably with changes in temperatures. FIGURE 3.11 Effect of cutting speed on cutting
temperature (theoretical).
To obtain more accurate predictions, the relationships
between the thermal properties of the material and It can be seen from the figure:
temperature must be known and used in calculations. 𝜃𝑠 increases slightly with increasing cutting speed v.
𝜃𝑚 + 𝜃𝑠 increases rapidly with increasing cutting speed v.
3-15
Chapter 3: Temperatures in
ME4870: Machining – J Lieh
Metal Cutting
3-16
Chapter 3: Temperatures in
ME4870: Machining – J Lieh
Metal Cutting
3.4.2 Direct Thermocouple Measurements In these experiments the rig was first run without
Direct thermocouple measurements can be made during cutting, and the reading of the millivoltmeter resulting
cutting. The results in Figure 3.7 were obtained using a from the rubbing action of the constantan wire on the
thermocouple technique illustrated in Figure 3.14. workpiece was noted.
3-18
Chapter 3: Temperatures in
ME4870: Machining – J Lieh
Metal Cutting
This reading was subsequently subtracted from the 3.4.3 Radiation Methods
readings taken while cutting was in progress.
When the tool-workpiece can be observed directly,
With this method, the temperature at selected points camera and film sensitive to infrared radiation can be
around the end of the tubular workpiece were measured used to determine temperature distributions.
and then used to calculate the proportion of the shear-
Some of the experimental results are shown in Figure 3.7
zone heat conducted into workpiece.
and experimental confirmations of the curves in Figure
Direct measurements of temperatures can be made by 3.9 were obtained by this method.
making a hole in the tool close to the cutting edge and
Miniature electronic photo detectors arranged in a focal
inserting a thermocouple to measure the temperature at a
plane array system enable temperature distributions to be
particular position.
determined with resolutions as low as 5 μm.
This can then be repeated with holes in various positions
to give an estimate of the temperature distributions. 3.4.4 Hardness and Microstructure Changes in
Steel Tools
However, significant errors may occur The hardness of hardened steel decreases after reheating,
Where the temperature gradients are steep, as the and the loss of the hardness is related to the temperature
holes for the thermocouples may cover a considerable and time of heating.
range of temperature
The hardness decrease is the result of changes in the
The presence of the holes may distort the heat flow microstructure of the steel. The structural changes can be
and temperature fields in the tool observed using optical and electron microscopes.
3-19
Chapter 3: Temperatures in
ME4870: Machining – J Lieh
Metal Cutting
These changes provide an effective means of determining The main limitation of this method of temperature
temperature distributions in the steel during cutting. estimation is that it can be used only within the range of
cutting conditions suitable for high-speed steel and when
Microhardness measurements on tool after cutting can be
relatively high temperature are generated.
used to determine constant-temperature contours in the
tool, but the technique is time-consuming and requires
very accurate hardness measurements.
The structural changes in the material takes place
gradually, but it has been observed that for some high- Homework Chapter 3
speed steels distinct modifications occur at approximately
50oC intervals between 600 and 900oC.
Problem 2