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CUTTING
Thermal Aspects
in Metal Cutting
Structure
2.1 Introduction
Objectives
Tool-work Thermocouple
2.3.2
Calorimetric Method
2.6 Summary
2.7 Key Words
2.8 Answers to SAQs
2.1 INTRODUCTION
During metal cutting, large amount of heat is produced in the region surrounding the
cutting edge. This leads to very high temperature at the tool-chip interface. The high
temperature of the tool leads to high tool wear rate (TWR), hence, the temperature
analysis in metal cutting has attracted many researchers. The measurement of temperature
of tool, chip and workpiece has been studied in depth.
The temperature of the cutting tool in machining is of great significance from the tool life
point of view. In the absence of careful selection of process parameters, the tool may get
overheated at the isolated locations resulting in localized damage. This may lead to
softening of the tool surface, or crack formation which ultimately leads to the failure of
the tool. Further, intense heating of the machined workpiece may also change its surface
properties. In view of this, an understanding of the thermal phenomenon in machining
becomes quite important.
Objectives
After reading this unit, you should be able to understand
how the temperature at tool surface and work surface can be measured,
31
32
the cutting process. Hence using this method temperature measurement at limited number
of locations on the tool face is possible. Boothroyd (1963) used infra-red photography to
determine temperature on the outside surface of the tool, work and chip. Some synthetic
materials (thermosensitive paints) have characteristic of changing their colour when
subjected to a definite range of temperature. This feature of synthetic materials is utilized
to measure temperature distribution on the tool. This method can be used to determine
approximate temperature distribution on the flank face of the tool and on the workpiece.
However, it is difficult to identify the exact colour and its location. Further, this method
cannot be used to determine temperature distribution on the rake face of the tool.
Thermal Aspects
in Metal Cutting
Due to high temperature at the cutting edge, many times the tool fails by plastic
deformation. Moreover, temperature gradient at the tool face is very high. It is therefore
necessary to know the actual temperature distribution along the rake face. Very fine blind
holes are drilled in the tool in which thermocouples are embedded to measure
temperature at different points (Figure 2.2). In this method, the temperature is measured
at some point below the tool surface because the drilled holes in the tool are not through
holes, otherwise thermocouples will get damaged and the cutting conditions will also
change significantly. Due to this, the difference in the actual and the measured rake face
temperature may be as high as 100C. The limitations of this method are due to response
time of thermocouples, bead size of thermocouple, and drilling of very fine holes in very
hard tool materials. Electrochemical machining (ECM), electric discharge machining
(EDM) or laser beam machining can be used to drill fine holes in electrically conducting
tool materials.
33
The emf generated may range anywhere from 2-15 mV depending upon tool-work
combination and the cutting conditions which control the tool-chip interface temperature.
Figure 2.3 : Schematic Diagram to Measure Tool-chip Interface Temperature Using Thermocouple
(or Tool-work Thermocouple) Technique
. . . (2.1)
. . . (2.2)
From the observations of the above three experiments as written in Eqs. (2.3)-(2.5) and
Eqs. (2.1) and (2.2), percentage of heat going to chip, tool and workpiece can also be
calculated.
H c + H w = H cal + H wat
(Experiment 1)
. . . (2.3)
. . . (2.4)
H c = H cal + H wat
. . . (2.5)
(Experiment 3)
Figure 2.4(b) shows the variation in percentage distribution of total cutting heat energy
with a cutting speed. It was concluded that the distribution of heat in chip, workpiece and
tool is approximately 80%, 10% and 10%, respectively beyond a certain minimum
cutting speed. This distribution would change to some extent by changing tool-work
34
combination and cutting conditions. The average tool-chip interface temperature (c) in
excess of room temperature can be determined from Eq. (2.6)
c mc Cc = H c
Thermal Aspects
in Metal Cutting
. . . (2.6)
where, mc and Cc are mass of the chip and specific heat of the chip, respectively. Here, it
is assumed that there is no loss of heat due to radiation.
Figure 2.4(b) : Distribution of Total Cutting Energy Between Chip, Tool and Workpiece in Drilling
. . . (2.7)
35
Figure 2.5 : Temperature Distribution in Workpiece and Chip during Orthogonal Cutting (Obtained
from an Infrared Photograph) for Free-cutting Mild Steel where the Cutting Speed is 75ft / min
(0.38m/s), the Width of Cut is 0.25 in. (6.35 mm), the Working Normal Rake is 30, and the Workpiece
Temperature is 611C. (After Boothroyd)
Ts =
where,
(1 R) Ps
w C w Vc tu b
36
. . . (2.8)
Thermal Aspects
in Metal Cutting
. . . (2.9)
where,
1
K
1 +1.328
Vc tu
. . . (2.10)
k
(Thermal diffusivity of the work
w C w
material).
Temperature Rise in SSDZ
Heated chip coming out of the PSDZ slides over the rake face of the tool. Due to
severe rubbing between the underneath of the chip and the rake face of the tool,
heat is generated (i.e., tool-chip interface also acts as a heat source). Friction
energy per unit area per unit time liberated as heat over the tool-chip contact
region is given by :
Ef =
where,
FV f
lb
Suppose, this heat source raises temperature of the chip by Tf, then temperature
of the chip (Tc) is given by
Tc = Ts + Tf + To
. . . (2.11)
T f =
0.75 R ' E f (l / 2)
k L
. . . (2.12)
V f (l / 2 )
2K
Vf l
4K
. . . (2.13)
37
k
(Here, it is assumed
w Cw
that thermal properties of workpiece and chip material are the same.) It is difficult
to estimate the value of R'. The approximate value of R' can be evaluated from the
following formula (Eq. (2.14)) which is derived on the same concept as that of R in
Eq. (2.10).
Ef l A
K3
R =
Ef l A
K3
where,
s + To
E f 0.377l
. . . (2.14)
K3 L
In metal machining, the coefficient of friction between the tool-chip interface based on
the above assumptions is normally high (often >1) and varies widely over the cutting
conditions.
In reality the sliding surfaces comprise peaks and valleys. The actual contact between the
two sliding surfaces is through the peaks (or asperities). Hence, the real area of contact
(Ar) is much smaller than the apparent area of contact (Figure 2.6). This real area of
contact changes with load which first causes elastic deformation and then plastic
deformation. It has been shown that under the influence of normal and tangential load,
very high temperatures are developed at the contacting asperities. Thus, sliding of one
surface relative to the other will shear the bonds (or welds) between the asperities. The
friction mechanism that operates in metal cutting is different when the plastic
deformation takes place at the contacting surfaces because the real area of contact
approaches that of apparent area of contact. Under such conditions, the friction force (F)
becomes independent of normal force (N) ( F N ) .
It has been found experimentally that the value of increases with increase in rake
angle. Increase in rake angle () decreases both the friction and normal force but
disproportionately (Table 2.1). As a result, the value of increases in contradiction to the
normal belief that would decrease with increase in .
38
Table 2.1
Rake Angle,
Friction Force, F
Normal Force, N
Coefficient of
Friction,
(N)
(N)
16
3025
4518
0.67
30
2524
2938
45
2470
2034
% Decrease
F
0.86
16.87
35
1.21
18.62
35
Thermal Aspects
in Metal Cutting
In metal cutting, friction along the rake face of the tool has been idealized as partially
sticking and partially sliding. (Figure 2.7). In sticking zone, shear stress () approaches
yield stress of work material (s) while in sliding zone it follows Coulomb's law of
friction ( = ; is normal stress). It is also seen in Figure 2.7 that normal stress in
contact zone is highest at the tool tip and zero at a point where the chip leaves the rake
face.
Under the cutting conditions employed in practice, friction stress on the tool face is so
large that over a part of contact length, lower contact layer of the chip is retarded (or
seized) and the process of external friction is replaced by internal plastic shear (or
secondary shear deformation). Mean coefficient of friction between chip and rake face of
the tool is influenced by tool geometry (rake angle and inclination angle of cutting edge)
and cutting conditions.
Under moderate cutting conditions (temperature at tool-chip interface is not very high), it
is found that the mean coefficient of friction () is manifested almost exclusively through
the variation in specific normal load (qN) since the specific tangential load (qF) remains
almost unchanged
=
where, qF =
qN =
qF
qN
. . . (2.15)
F
, and
lb
N
.
lb
. . . (2.16)
. . . (2.17)
39
where, e is coefficient of external friction (sliding friction) between the chip and the
tool face.
Figure 2.7 : Normal and Shear Stress Distribution on the Rake Face of the Tool
As soon as the tangential stress reaches a value equal to the shear flow stress of the chip
material, it becomes constant (Eq. (2.18)).
= s
. . . (2.18)
The value of the coefficient of friction in the sticking region is not constant, and its value
is lower than that in the sliding region. The estimated value of the coefficient of friction
in metal cutting is an average value based on the values of the friction coefficient in
sticking and sliding regions. Any change in cutting conditions will change l1 and l l1,
and hence the average value of the friction coefficient.
The tangential force (Fe) in external friction section (l l1) is given by
l l1
or,
(l l1 ) n +1
K4
n +1
. . . (2.19)
s = K 4 e (l l1 ) n (at x = l l1)
. . . (2.20)
Fe = b e
From Eq (2.17),
Fe = b s
(l l1 )
n +1
. . . (2.21)
According to Figure 2.7, the tangential force Fs in the plastic shear zone is equal to
Fs = bl1 s
. . . (2.22)
The tangential force (F) acting over the whole area of contact is the sum of the forces
acting in both zones.
F = Fs + Fe
= b s l1 + b s
or,
40
(l l1 )
n +1
(l l1 )
F = b s l1 +
n + 1
. . . (2.23)
The term within bracket in Eq. (2.23) remains almost constant, hence F depends on the
shear resistance of the lower layer of the chip (b is constant for orthogonal cutting). At
moderate cutting conditions, s remains approximately constant, hence
constant
N
Thermal Aspects
in Metal Cutting
. . . (2.24)
N = K 4 b x n dx
. . . (2.25)
N =b
or,
n +1
l
K4
n +1
. . . (2.26)
N=
Therefore,
. . . (2.27)
b m l
n +1
. . . (2.28)
n +1
e =
l
m
n + 1
or,
a =
. . . (2.29)
s nl1
+ 1
m l
. . . (2.29(a))
l
e = s
m (l l1 )
. . . (2.30)
Thus, using above equations the average value of coefficient of friction and the
coefficient of friction in sliding zone (a and e) can be evaluated.
Parameter
Symbol
Unit
1.
Temperature
2.
Cutting speed
Vc
LT-1
41
3.
Chip area
Ao
L2
4.
Sp
ML-1T-2
5.
MLT-3D-1
6.
ML-1T-2D-1
In Table 2.2, there are six variables and four known dimensions (M, L, T, D) hence we
can form two dimensionless groups, say, Q1 and Q2 as follows :
Q1 = V a S Pb K c ( c ) d
. . . (2.31)
Q2 =V e S Pf K g ( c) h Ao
. . . (2.32)
or,
Q1 = M
b+c+d
La b + c T
a 2 b 3c 2 d
c d + 1
. . . (2.33)
Since Q1 is a dimensionless quantity, the index for each term in Eq. (2.33) should be
zero. From Eq. (2.33), it is, therefore, possible to write :
b+c+d=0
. . . (2.34(a))
ab+cd=0
. . . (2.34(b))
a 2b 3c 2d = 0
. . . (2.34(c))
cd+1=0
. . . (2.34(d))
There are four unknowns (a, b, c, d) and four equations hence the values of unknowns
can be evaluated. They are as :
a = 0, b = 1, c = 0, d = + 1
. . . (2.34(e))
Substituting the values of a, b, c and d from Eq. (2.34(e)) into Eq. (2.31) we get :
Q1 = S P 1 (c) =
c
SP
. . . (2.35)
Vc2 (c) 2 Ao
. . . (2.36)
k2
or,
V 2 (c) 2 A o
(c)
= Co c
SP
k2
Experimentally for mild steel turning, it has been shown that n = 0.22,
or,
= Co S P
Vc0.44 Ao0.22
k 0.44 (c) 0.56
. . . (2.37)
By independent experimentation and analysis of results, Shaw showed that the important
parameters in metal cutting are work properties, strength, and thermal properties
(k, , c), and cutting conditions (V, f, ).
42
Thermal Aspects
in Metal Cutting
Parameter
Symbol
Unit
1.
Temperature
2.
Tool life
3.
Area of cut
Ao
4.
Cutting speed
Vc
LT
5.
Specific pressure
Sp
ML T
6.
ck
ck
M T D
2
-1
-1 -2
2 -5 -2
For six variables and four dimensions (6 4 = 2) the following two dimensionless
parameters, Q3 and Q4 can be formed :
c
Q3 = T a Vcb S P (ck ) d
g
Q4 = T e Vc f S P (ck ) h Ao
. . . (2.38)
. . . (2.39)
Substituting the dimensions in Eqs. (2.38) and (2.39) as in the previous analysis, we can
obtain :
Q3 =
(ck ) 0.5
T 0.5 ( S p )Vc
. . . (2.40)
Ao
2 2
Vc T
. . . (2.41)
C1 AomVc1 2 mT 0.5 2 m S P
(ck ) 0.5
. . . (2.42)
Here, C1, Ao, ck, Sp and Vc can be treated as constant ( C ) during turning. Hence,
x
T =C
. . . (2.43)
It is evident that any attempt to increase the temperature of the tool will decrease the tool
life, but not linearly. Hence, usually coolant is used to keep the tool at as low temperature
as possible to increase its life.
Example 2.1
Name (no discussion) different sources of heat generation in metal cutting. Show
that for orthogonal machining with zero degree rake angle tool, the rate of heat
generation in metal machining (PSDZ) can be expressed as
Fc Vc (1 rc )
J
where,
Fc = cutting force,
43
Vc = cutting speed,
= coefficient of friction,
rc = chip thickness ratio, and
J = mechanical equivalent of heat.
Solution
In metal cutting, there are three sources of heat generation: PSDZ, SSDZ and tool
work (machined surface) interface.
F V
Heat generation rate in PSDZ, Qs = s s
J
where,
Fs = shear force,
Vs = shear velocity, and
J = mechanical equivalent of heat.
Fc = R cos ( )
Fs = R cos ( + )
For = 0,
Fs = c
= Fc
cos
cos
Vc
cos
Also,
Vs =
for = 0
Qs = Fc
cos () (1 rc ) Vc
J cos
Qs = Fc
(1 rc ) Vc
J
Hence, proved.
Example 2.2
Determine the value of mean coefficient of friction in SSDZ for the following
conditions. The ratio of tool chip contact length to the length of sticking friction
zone is 2.0. The ratio of maximum normal stress to maximum shear stress is also
2.0. The normal stress follows the following relationship
= x2
( K 4 = 1.0)
where, x is the distance measured along the rake face of the tool with tool point as
the origin.
Solution
l l1
F1 =
Thermal Aspects
in Metal Cutting
e b d x
= e b
l l1
x 2 dx (as given)
F1 = e b
or,
(l l1 )
3
m = xm2
But,
= l2
Also,
m = e (l l1 )
(at x = (l l1 )
l l1
F1 = m l
. . . (E 2.1)
l l1
= m b
+ m l1 b
3
(l l1 ) + 3l1
= m b
2l +
= m b 1
3
N=
bdx
=b
N=
x3
x dx = b
3 0
2
bl 3 b m l
=
3
3
e =
Also as given, l = 2l1 and
F mb [l1 + (l l1 ) / 3]
=
N
b m (l / 3)
m
=2
m
a =
1
2
2 l1 l1
l1 + 3
2 l1
3
1
[4 l1 / 3]
=2
2 l1
3
hence,
a = 1.0
Example 2.3
Solution
From the given data and taking into consideration the nature of stress distribution
as given in the figure, we compute :
Normal force = b Area of ABC Width of cut.
N=
max l b
2
2000 0.75 6
2
10 10
N = 45 kg
Also,
F = max l1 b +
= 900
max (l l1 ) b
2
0.25 0.6
1
0.50
0.60 + 900
10
2
2
10
= 27 + 6.75 = 33.75 kg
F = 33.75 kg
46
F 33.75
= =
= 0.749
45
N
Thermal Aspects
in Metal Cutting
= 0.75
It is also known that
= tan = 0.749
= 36.8 o
R=
N
45
=
= 56.25 kg
cos 0.8
R = 56.25 kg
SAQ 1
(a)
(b)
(c)
(d)
(e)
(f)
True
(ii)
False
True
(ii)
False
(ii)
(iii)
(iv)
none of these
Tool life while cutting with coolant is more than dry cutting. It is the
result of
(i)
cooling of tool
(ii)
(iii)
(iv)
none of these
less
(ii)
more
(iii)
equal
(iv)
difficult to determine
Use of a thermocouple embedded in the tool in metal cutting will give the
tool temperature which is
(i)
average
(ii)
highest
(iii)
temperature at a point
(iv)
none of these
47
(g)
(h)
(i)
10%
(ii)
50%
(iii)
90%
(iv)
none of these
obeyed
(ii)
not obeyed
(iii)
more
(ii)
less
(iii)
2.6 SUMMARY
There are three sources of heat generation, e.g., PSDZ, SSDZ and tool (flank face) work
interaction. As a result of heat generation, the temperature of tool, workpiece and chip
increases. Maximum temperature rise occurs at the tool rake face. It softens the tool
material which enhances the tool wear rate, and sometimes may lead to sudden failure of
tool as well. The rise in temperature of workpiece is also of concern. But this rise in
temperature of workpiece is safe in the sense that usually it does not result in phase
transformation but may change to some extent the surface or sub-surface properties of the
machined surface and may affect the machining accuracy.
There are various ways to measure the tool and workpiece temperature at a point
(pyrometer, and embedded thermocouple). Calorimetric method gives average
temperature of chip, workpiece and tool. However, most commonly used method is toolwork thermocouple which gives tool (average tool chip interface) temperature.
Theoretically, researchers have reported point to point variation of temperature on the
tool, chip and workpiece surfaces. Analytical calculation of rise in temperature in PSDZ
has been done using Jaeger's moving heat source model. The procedure also has been
proposed to calculate percentage of the total heat going to the chip, tool and workpiece.
The analysis has been presented to calculate the coefficient of friction in the sticking
zone and sliding zone in the SSDZ. In the sliding zone, the value of may be even more
than 1.0 which is not the case according to the Coulomb's law of friction ( =F/N).
Finally, the dimensional analysis has been presented to establish relationship between
cutting temperature and identified variables. The relationship between tool life and
temperature has also been developed using dimensional analysis theory.
48
Thermal Aspects
in Metal Cutting
Jaeger's Model
Dimensional Analysis
(a) (ii)
(b) (i)
(c) (i)
(d) (iii)
(e) (ii)
(f) (iii)
(g) (i)
(h) (ii)
(i) (iii)
NOMENCLATURE
A
Area factor
Ao
Chip area
Ar
Cc
Cw
Temperature
Ef
Fe
Fs
Hc
Hcal
Ht
Hw
Hwat
49
50
K3
Length
mc
Mass
Normal force
Pm
Pc
Pw
Pt
Ps
qN
qF
rc
1-R
Sp
tu
Time
Tc
To
Ambient temperature
Vc
Vs
Vf
Rake angle
Shear strain
Coefficient of friction
Coefficient of external friction (sliding friction) between the chip and the tool
face
Temperature
Normal stress
Rise in temperature
Ts
Tf
ACRONYMS
ECM
Electrochemical machining
EDM
Thermal Aspects
in Metal Cutting
EXERCISES
Q 1.
How can you determine the temperature of the chip using Schmidt's calorimetric
method during drilling? What is the expected percent of heat distribution in chip,
work and tool?
Q 2.
Q 3.
During machining (using shaper), the rise in temperature of the chips was found
to be 600C with the help of a calorimeter. The cutting was done at 2 m/s with
feed rate (tu) as 0.5 mm, width of cut as 3 mm using a tool with rake angle = 45.
Dynamometer records Fc = 6000N and Ft = 0. Under microscope, chip thickness
was found as 1.1 mm, and the workpiece length was 300 mm. After 50 strokes
(in one stroke, it will cut only 300 mm length), the insulated workpiece was
immersed in a calorimeter and its additional heat content was found to be 30 kJ.
Neglect the heat conducted into the cutting tool, calculate the proportion of the
PSDZ heat conducted into the workpiece (make the appropriate assumptions if
required).
51
BIBLIOGRAPHY
Armarego, E. J. A. and Brown, R. H., (1969), The Machining of Metals, Prentice Hall,
Englewood Cliffs, NJ.
Bhattacharyya, A. (1984), Metal Cutting : Theory and Practice, Central Book Publishers,
Calcutta.
Boothroyd, G. (1975), Fundamentals of Metal Cutting and Machine Tools, McGraw-Hill
Kogakusha Ltd., Tokyo.
Boothroyd, G. (1963), Temperature in Orthogonal Metal Cutting, Proc. IME,
Vol. 177, p.789.
Kalpakjian, S. (1989), Manufacturing Engineering and Technology, Addison Wesley
Publishing Co., New York.
Pandey, P. C. and Singh, C. K. (1998), Production Engineering Sciences, Standard
Publishers Distributors, Delhi.
Rao, P. N. (2000), Manufacturing Technology : Metal Cutting and Machine Tools, Tata
McGraw-Hill Publishing Co. Ltd., New Delhi.
Shaw, M. C. (1984), Metal Cutting Principles, Oxford, Clarendon Press.
52