FE analysis of cutting tool temperature field with adhering layer formation
TL;DR: In this article, the cutting tool temperature field with adhering layer formation when machining free-cutting stainless steel was investigated by means of combining thermocouple measuring method and finite element (FE) analysis.
About: This article is published in Wear.The article was published on 1998-02-01. It has received 18 citations till now. The article focuses on the topics: Cutting tool & Layer (electronics).
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TL;DR: In this article, a review of widely used temperature measurement methods and how they can be applied to temperature monitoring during material removal is presented, using criteria critical in measuring material removal, and the results presented in guide-format for participants in this field of work.
345 citations
TL;DR: In this paper, the mechanism of minimum quantity lubrication (MQL) in high-speed machining of hardened steels is investigated more comprehensively and it is found that MQL can provide extra oxygen to promote the formation of a protective oxide layer in between the chip-tool interface.
Abstract: The rapid wear rate of cutting tools due to high cutting temperature is a critical problem to be solved in high-speed machining (HSM) of hardened steels. Near-dry machining such as minimum quantity lubrication (MQL) is regarded as one of the solutions to this difficulty. However, the function of MQL in HSM is still uncertain so far which prevents MQL from widely being utilized in the machining of hardened steels. In this paper, the mechanism of MQL in HSM of hardened steel is investigated more comprehensively. Comparing with dry cutting, the tool performance can be enhanced by MQL under all cutting speeds in this study. It is found that MQL can provide extra oxygen to promote the formation of a protective oxide layer in between the chip–tool interface. This layer is basically quaternary compound oxides of Fe, Mn, Si, and Al, and is proved to act as diffusion barriers effectively. Hence, the strength and wear resistance of a cutting tool can be retained which leads to a significant improvement of tool life. It is found that there exists an optimal cutting speed at which a stable protective oxide layer can be formed. When cutting speed is lower than this speed, there is less oxide layer and the improvement of tool life is less apparent. As the cutting speed is far beyond the optimal value, the protective layer is absent and the thermal cracks are apt to occur at the cutting edge due to large fluctuation of temperature. Resultantly, application of MQL is inappropriate in the extreme high-speed cutting condition irrespective of its little increase in tool life. Based on this study, it is concluded that the tool life can be effectively improved by MQL in HSM of NAK80 hardened steels when cutting parameters are chosen properly.
160 citations
Cites background from "FE analysis of cutting tool tempera..."
...[31] that cutting temperature is the most important factor to influence the formation of the adhering layer; and there exists an optimal range of cutting temperature at which a stable layer with largest proportion of inclusion elements could be formed....
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TL;DR: In this paper, a bibliographical review of the finite element methods applied to the analysis and simulation of welding processes is given, which are classified in the following categories: modelling of welding process in general; modelling of specific welding processes; influence of geometrical parameters; heat transfer and fluid flow in welds; residual stresses and deformations in weld, fracture mechanics and welding; fatigue of welded structures; destructive and non-destructive evaluation of weldments and cracks; welded tubular joints, pipes and pressure vessels/components; welds in plates and other
Abstract: This paper gives a bibliographical review of the finite element methods applied to the analysis and simulation of welding processes The bibliography is an addendum to the finite element analysis and simulation of welding: a bibliography (1976–96) published in Modelling Simul Mater Sci Eng (1996) 4 501–33 The added bibliography at the end of this paper contains approximately 550 references to papers and conference proceedings on the subject that were published in 1996–2001 These are classified in the following categories: modelling of welding processes in general; modelling of specific welding processes; influence of geometrical parameters; heat transfer and fluid flow in welds; residual stresses and deformations in welds; fracture mechanics and welding; fatigue of welded structures; destructive and non-destructive evaluation of weldments and cracks; welded tubular joints, pipes and pressure vessels/components; welds in plates and other structures/components
128 citations
TL;DR: In this paper, a thermal analysis model is developed to determine temperature distribution in orthogonal metal cutting using finite elements method, which calculates the temperature distribution as a function of heat generation.
68 citations
TL;DR: In this paper, the authors investigated tool wear mechanisms for an end milling operation of a precipitation-hardened martensitic stainless steel under four different cooling and lubrication conditions.
Abstract: Most of the machining operations on stainless steel alloys are carried out with cutting fluid due to the poor machinability of this kind of material. Tool wear mechanisms are directly influenced by the cooling and lubrication condition to which the tool is exposed, especially in interrupted cutting processes. This work investigates tool wear mechanisms for an end milling operation of a precipitation-hardened martensitic stainless steel under four different cooling and lubrication conditions. The results demonstrated that the cooling and lubrication condition strongly influences tool life and the tool wear mechanism, and furthermore, that tool lubrication rather than cooling should be the purpose for using cutting fluid in this kind of operation, in order to avoid damage caused by tool temperature variations.
51 citations
Cites background from "FE analysis of cutting tool tempera..."
...Tieu et all [4] carried out several dry turning experiments of Ca-S free-cutting austenitic stainless steel to investigate adhering layer formation on the tool....
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...The formation of a layer adhering on the tool rake face is facilitated by the large amount of heat generated [4]....
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References
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01 Jun 1974
TL;DR: In this paper, the temperature distribution for typical cases of orthogonal machining with a continuous chip was obtained numerically by solving the steady two-dimensional energy equation using the finite element method.
Abstract: Temperature distributions for typical cases of orthogonal machining with a continuous chip were obtained numerically by solving the steady two-dimensional energy equation using the finite element method. The distribution of heat sources in both the primary and secondary zones was calculated from the strain-rate and flow stress distributions. Strain, strain-rate and velocity distributions were calculated from deformed grid patterns obtained from quick-stop experiments. Flow stress was considered as a function of strain, strain-rate and temperature. The chip, workpiece and tool (actual shape and size) were treated as one system and material properties such as density, specific heat and thermal conductivity were considered as functions of temperature.
198 citations
158 citations
TL;DR: In this article, the finite element method is applied to calculate the temperatures in orthogonal machining with account being taken of the finite plastic zones, in which the chip is formed and in which further plastic flow occurs at the tool-chip interface, and also of the shape and thermal properties of the cutting tool.
148 citations
TL;DR: In this paper, Cemented carbide inserts, both uncoated and coated with single or composite layers of TiC, TiN, or Al2O3, were used to cut En. 8 and En 24 steel at speeds between 183 and 305 min−1.
Abstract: Cemented carbide inserts, both uncoated and coated with single or composite layers of TiC, TiN, or Al2O3, were used to cut En. 8 and En 24 steel at speeds between 183 and 305 min−1 Quick-stop specimens and tool-temperature estimates demonstrated that conditions at the tool/work interface were essentially similar for uncoated tools and for all types of coated tool tested. The flank and rake-face wear rates of coated tools were estimated to be respectively ∼ 10 and 100 times less than that of an uncoated carbide, smaller differences between the rates of flank and rake-face wear of TiC, TiN, and Al2O3 coatings being observed. On the rake face, wear of TiC coatings was by atomic diffusion and discrete plastic deformation, while TiN coatings and uncoated cemented carbide were worn by atomic diffusion. Al2O3 coatings were worn principally by discrete plastic deformation. Flank wear of both coated and uncoated tools was principally by atomic diffusion. Al2O3 and TiN coatings showed a greater resistance t...
129 citations