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Heat Generation N Cutting Temperature

The document discusses heat generation and cutting temperature in machining, detailing sources of heat, effects on tools and jobs, and the importance of measuring cutting temperature. It outlines methods for temperature measurement, including analytical and experimental techniques, and emphasizes the need for controlling cutting temperature to improve machinability and tool life. Additionally, it provides problem-solving examples for estimating shear zone and interface temperatures in machining processes.

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maityarnab909
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22 views26 pages

Heat Generation N Cutting Temperature

The document discusses heat generation and cutting temperature in machining, detailing sources of heat, effects on tools and jobs, and the importance of measuring cutting temperature. It outlines methods for temperature measurement, including analytical and experimental techniques, and emphasizes the need for controlling cutting temperature to improve machinability and tool life. Additionally, it provides problem-solving examples for estimating shear zone and interface temperatures in machining processes.

Uploaded by

maityarnab909
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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HEAT GENERATION & CUTTING

TEMPERATURE IN MACHINING
Sources and causes of heat generation

Primary shear zone (1) where the


major part of the energy is
converted into heat

Secondary deformation zone (2) at


the chip – tool interface where
further heat is generated due to
rubbing and / or shear

At the worn out flanks (3) due to


rubbing between the tool and the
Finished surfaces
Sharing of heat among chip, tool & workpiece
Effect of cutting temperature on tool
On tool:-
□ Rapid tool wear that reduces tool life

□ Rapid failure of cutting edge and tool tip by


plastic deformation of the cutting tip, if the tool
material is not enough hot hard and hot strong

□ thermal flaking and fracturing at the cutting


edge

□ built-up-edge formation
Effect of cutting temperature on job
On job:-
• Dimensional inaccuracy due to thermal
distortion & expansion-contraction during & after
machining
• Poor surface finish due to BUE and damage of
the cutting edge
• Surface damage due to oxidation, burning, rapid
corrosion.
• Induction of tensile residual stresses and
micro-cracks at surface.
Need of measurement of cutting
temperature
❑ Assessment of machinability

❑ Design and selection of cutting tools

❑ Evaluate the role of variation of the different machining


parameters on cutting temperature

❑ Proper selection and application of cutting fluid

❑ Analysis of temperature distribution in the chip, tool and


job.
Basic two methods of measurement of cutting
temperatures

• Analytical method – easy, quick but inaccurate


• Experimental methods – accurate and precise but may be
difficult and expensive

Vf
2
1

VC
3
Cutting temperature Measurement

Analytical estimation of cutting temperature,


Average shear zone temperature, θS
Generally A varies from
0.95 to 1.0 and q from
0.7 to 0.9 in machining
like Turning
Average chip – tool interface
temperature, θi
Use Buckingham’s Theorem
Cutting temperature Measurement
Experimental methods
• tool-work thermocouple technique
• moving thermocouple technique
• embedded thermocouple technique
• using compound tool
• indirectly from microhardness distribution
• photo-cell technique
• infra-ray detection method
Tool-work thermocouple – simple and
inexpensive but gives only average or maximum
value
Moving thermocouple technique :-A bead of
standard thermocouple like chrome-alumel is brazed on the side
surface of the layer to be removed from the work surface and
the temperature is attained in terms of mV
Embedded thermocouple technique:-
Measurement of chip-tool interface temperature by
Compound tool:-
Photo-cell technique :-
Infra-red photographic technique :-
Conti..

Infrared camera
Role of variation of the various machining parameters
on cutting temperature
Role of variation of the various
machining parameters on cutting
temperature
Empirical relation
How to control cutting temperature
Exercise 2.7

Problem 1
Analytically estimate the average shear zone temp., θs for
plain turning of a mild steel rod by a carbide tool of geometry
–6o, -6o, 6o, 6o, 15o, 75o, 1.2 (mm) NRS at feed 0.12 mm/rev
and depth of cut 3.0 mm under dry condition when the
followings were noted: Pz= 1200 N, Frictional force, F = 500
N & a2= 0.6 mm
Assume : 80% of mechanical energy gets converted into
heat & 90% of the heat generated at the shear zone goes
into the chips, Mechanical equivalent of heat, J = 4.2 J/Cal
Vol. specific heat of mild steel,cv= 825 kCal/m3oC
Ambient temperature, θa = 25o

Solution follows ………


Solution -

• The general expression for average shear


zone temperature, θs is,

θs = Aq(PzVc — FVf) /(JcvV ts ) + θ


c o a

= Aq(PZ – F/ ζ)/(Jc ts ) + θ
v o a
• where given,
A = 0.8 so= 0.12 mm/rev q = 0.9 t = 3.0 mm

Pz = 1200 N J = 4.2 J/Cal cv = 825 Kcal/m / C


3 0

• ζ = a /a2 1
= a /s sinφ given a = 0.6 and φ = 75
2 o 2
o

∴ ζ = 0.6/(0.12xsin75 ) = 5.176
o

0.8x0.9(1200 – 500/5.176)
θs= + 25 = 643o C
4.2 x 825 x 0.12 x 3 x 10-6 ans
Problem 2
From dimensional analysis,
Q1= ρv θI/Ec and Q2= (Va1/ ρv λ)2
where Q1= C1.Q20.25 and C1 is a constant, = 121.
Material-A is machined at 150m/min and feed of 0.2 mm/rev under orthogonal turning
with principal cutting edge angle,φ = 90o
Determine the interface temp. θi for this material?
Given:

Properties λ ρv σu Δ ζ
Kcal/m-hr-sec Kcal/m3/oC Kg/mm2
Material A 40 800 40 0.2 2.5
Solution of Problem 2
• Given the relations :
Q1= ρv θI/Ec
Q2= (VCa1/ ρv λ)2
and Q1= C1.Q20.25
• Combining those equations :
θI = C1Ec(Vca1/ρv λ )0.5 where
θI = average chip-tool interface temp.
C1= constant = 121
Ec= specific cutting energy of the work
material by a given tool in a given
environment
Vc= cutting velocity, m/min
a1= uncut chip thickness, = sosinφ mm
• Ec = (Pz.Vc/tsoVc) = (tsoτsfVc)/(tsoVc)
= τsf N/mm2
where, τs = dynamic yield shear strength of the
work material
and f = form factor

• For material A
τ = 0.74Δσu60.6Δ ; σUA= 40 kg/mm2
Δ = 0.2 and f = ζA — tanγ + 1 ≅ ζA + 1=2.5+1=3.5

• Hence for material A


Ec= (0.74x40x60.6x0.2)x3.75 kg/mm2

• θiA = C1xECA(Vca1/ρvA λA)


given cv = 800, λA = 40 and C1=121
∴ θiA = 121 {ECA(Vca1/ cvA λA)0.5} = 500oC answer

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