World Journal of Science and Technology 2012, 2(4):15-19

ISSN: 2231 2587

Available Online: www.worldjournalofscience.com

Proceedings of "Conference on Advances in Mechanical Engineering (NCAME'12)

Held at R.C.Patel Institute of Technology, Shirpur, Dist. Dhule,Maharastra,India.
April 21, 2012

Development of temperature measurement setup for machining

Abhijeet Amritkar1,Chandra prakash1 and Atul P.Kulkarni1
1Department

of Mechanical Engineering, Vishwakarma Institute of Information Technology, Kondhwa (Bk.) Pune, M.S. India

Abstract
In modern industry, the trend towards using dry and high speed machining has caused much greater heat dissipation in the
chip formation zone and for this reason thermal phenomena play a key role in tool wear and machinability of the materials.
For the improvement of cutting performance, the knowledge of temperature at the tool-work interface with good accuracy is
essential. In this paper, calibration set-up was designed and developed in order to establish a relationship between obtained
e.m.f. during machining and the cutting temperature. Also, the most simplest and economical technique of temperature
measurement i.e. tool-work thermocouple set-up was developed for the measurement of the cutting temperature in machining.
The performance of the setup is evaluated for the different material like EN19, EN31, mild steel, SS 304 and SAE 8620. The
results obtained experimentally confirmed that the set-up is having
better
accuracy
and
good
repeatability.
Regression analysis is used for establishing the relationship between temperature and the generated voltage.
Machining
tests are carried out for SAE 8620 material for various cutting speed and feed using uncoated tungsten carbide tool. Cutting
temperatures are predicted.
Keywords: machining, tool-work thermocouple, tool wear, cutting temperature.
INTRODUCTION
WORKING PRINCIPLE
In manufacturing process, temperature has critical influence
on machining. It accelerates tool wear, shortening tool life. It causes
the thermal deformation of the work-piece, cutting tool and machine
tool, which degrades the machining accuracy; it affects the
subsurface layers of machined parts through phase transformation,
thermally induced residual stresses an increase in thermally
activated defects[1]. Abhang et al. [2] measured the tool-chip
interface temperature experimentally during turning of EN-31 steel
alloy with tungsten carbide inserts using a tool-work thermocouple
technique. Grzesik [4] dealt with experimental investigation into the
different factors which Influence the temperature which occur
at the coating/substratechip interface during machining of
medium carbon steel (AISI 1045) and an austenitic stainless steel
(AISI304). O'Sullivan et al. [6] demonstrated the use of embedded
thermocouples (in the work-piece) and the infrared thermal camera
to monitor the temperature during the process. To reduce
these defects, we developed a calibration setup on the basis of
Seebeck effect with the help of k-type thermocouple and
microcontroller. This setup helped us during calibration, resulted in
measuring the temperature during machining.

It works on a principle of Seebeck effect. According to

Seebeck, when two different metals are heated at a common
junction voltage exist between two ends of metals.
TECHNIQUES FOR ASSESING CUTTING TEMPERATURE

*Corresponding Author

Materials used during testing for calibration setup

EN-19, EN-31, mild steel, SS 304, and SAE 8620.
Workpiece used

Srihari Prasad A
Department of Mechanical Engineering, K.L.University, Vaddeswaram, Guntur,
A.P., 522502., India

The workpiece used during the experimentation is SAE 8620

steel. The dimensions used are 80 mm in diameter and 300mm in
length. The alloying elements of SAE 8620 steel are shown in table 1.

Email: srihari.anne@gmail.com

Srihari Prasad A et al.,

16
Table 1. Elemental composition of SAE 8620

Carbon%

Mn.% Cr%

Ni.% Mo.% Si.%

0.18

0.70

0.7

0.6

0.25

0.20

Tool insert used

The insert used during turning is CNMG 120404, grade k313.
This is uncoated tungsten carbide tool.
Experimental setup Experimental setup consists of
I. Tool work thermocouple setup
II. Calibration setup
III. Data acquisition system

Calibration setup
Calibration set-up is developed in order to establish the
relationship between the e.m.f. produced and cutting temperature
during machining. In calibration set-up, tool-work thermocouple
junction is constructed using a long continuous chip of different workmaterial and fresh tungsten carbide inserts used in actual machining
operation. Electric air heater is used to as a heating element for the
work-tool junction and it simulates the thermal performance
phenomena in machining and raised the temperature at the chip-tool
interface. Work-tool material and the thermocouple wire are heated
directly as they are in contact with the electric heater. A standard
alumel- chromel thermocouple wire is mounted at the junction of chip
and insert. It has high temperature range of -200 C to 1350C. It
has better oxidation resistance. Type-K sensors are recommended
for use in oxidizing or completely inert environments.

I. Tool work thermocouple setup

Tool and work-piece junction at the time of machining is taken
as hot junction while the carbon brush touching the
work-piece is cold junction. Work-piece is mounted on a three jaw
chuck and insulation is provided in between work-piece and jaw. One
end of connecting copper wire is attached to the carbon brush
and the other end to the millivolt-meter. Insulation is
provided between tool holder and insert. One end of connecting
copper wire is placed between insert and tool holder and the other
end to the millivolt-meter. Insulation is provided to avoid generation
of parasitic e.m.f. which is generated due to more than two metal
contacts. Copper wire of
1 mm diameter is used for the connection purpose.

a)

b)
Fig 3. Calibration set-up a) Front view b) top view
Fig1. Principle of work tool thermocouple

Fig 2. Photographic view of work tool thermocouple.

Fig 4.Block diagram of data acquisition system

World Journal of Science and Technology 2012, 2(4):15-19

17

The block diagram of the system is shown above. The system

consist of the following elements,
Temperature Sensor
Microcontroller
Display
Real time clock
Data storage Block
Temperature Sensor
The temperature sensor is the device which is responsible to
sense the temperature at the junction of machine tool and job.

2) After maintaining the proper contact, one end of the copper wire is
connected to the tool and chip material and other end was connected
to the milli-voltmeter terminals. Then electric air heater was brought
in contact with the junction point for heating the junction point.
3) A standard alumel-chromel thermocouple wire was mounted at the
junction of chip and insert. And it is connected to the temperature
indicator calibrated for the Type-K thermocouple wire.

i.

ii. Microcontroller
Microcontroller is the heart of the system that is controlling all
the processes. The controller PIC 18f4620 is used due to its
numerous advantages such as huge memory size, built in ADC, can
source high current, more power handling capacity, DIP package,
low cost etc.
iii. Display
The LCD Display is used to display the temperature of the job
according to the inputs of the controller. The display 16x2 is used
due to high range display and clear visibility and low cost.
iv. Data Storage
The data storage element can be a USB device or a memory
card interface for storing data. This storage is very useful for keeping
the track of the system temperature. This track can be used for
future studies, analysis, and to keep record of
temperature according to time n date.
v. Real Time Clock
Real time clock is used to store data with respect time n date.
RTC DS1307 is used for this purpose which is
interfaced with the microcontroller.

The

4) After this, whole assembly was kept in the container insulated with
glass wool in order to reduce heat losses and electric heater is
turned on and junction point was heated gradually up to
750 c and corresponding e.m.f. is recorded.
5) Graph of temperature v/s generated e.m.f. was plotted and
calibration constant is found out by using regression analysis.
RESULTS AND DISCUSSIONS
The objective of the experiment is to measure the
temperature during
machining
process.
So,
after
carrying
out
the experiment on the basis of Seebeck effect by
using calibration setup temperature for machining is calibrated and is
verified by using regression analysis.
Graphical representation
To find relationship between temperature and voltage, by
taking temperature on y-axis and voltage on x-axis. Different
materials were used during experiment to check validity, repeatability
and accuracy of the calibration setup.
The following graphs show temp.-voltage (m.v.) relationship for
different materials.
EN-19

Table 2.Time temperature voltage information

Fig 4.Temperature Voltage plot for EN-19.

EN-31.
Table 2 shows readings displayed by micro-controller. As
temperature increases voltage increases correspondingly and
TIME column represents exact time when temp and voltages are
measured.
EXPERIMENTAL PROCEDURE
1) First, work-piece chip and tool material to be calibrated were
clamped with the help of clamping assembly in the set- up. While
clamping, care was taken to ensure the perfect contact between the
work-tool materials because improper contact can result in the erratic
readings.

Fig 5. Temperature Voltage plot for EN-31.

Srihari Prasad A et al.,

18

SAE-8620
Table 3. Equations of lines for respective materials
SR. NO.

MATERIAL

EQUATION OF LINE

EN-19

Y=353.94X+94.15

EN-31

Y=174.52X+23.91

SAE-8620

Y=9.486X+20.63

Mild steel

Y=287.43X+11.2

Stainless steel

Y=10X+30

Temperature during machining SAE 8620.

Fig 6. Temperature Voltage plot for SAE-8620.

Mild steel

As setup validated by taking series of reading, the machining

tests were conducted on SAE8620 steel for different cutting speed
and feed. The depth of cut was kept constant at 1mm. During
machining the voltage is generated. By the use of regression
equation for the SAE8620 corresponding temperature was obtained.
Temperature obtained for different machining conditions are shown
in table 4.

Fig 7. Temperature Voltage plot for Mild Steel

Stainless steel 304

Temperature during machining of SAE 8620 steel for different

conditions.
Fig 8. Temperature Voltage plot for stainless steel 304

CONCLUSION

Regression analysis
From the graph, different value of voltage and corresponding
temperatures are obtained.In this way, graphical relationship of few
materials was obtained. During graphical representation equations
for respective lines were also obtained. it was
verified by using actual mathematical formulation for regression
analysis in statistics.
Formula for regression is
y = m.x + n.c . . . . . .(1)
xy = m.x2 + cx. . . . . .(2)
Here, y is taken as temperature value. whereas, x is taken as
voltage value. And n is no. of readings taken.

In this study, average chip-tool interface

temperatures
have been experimentally studied using the tool-work thermocouple
technique and validated theoretically.
The set-up is developed for the calibration and the temperature
measurement The set-up is tested for the different work-tool material
combinations. Both the set-ups are having better accuracy and good
repeatability.
The tool-work thermocouple technique is the best
method for measuring the average chip-tool interface temperature
during metal cutting. The benefits of using the tool
work thermocouple are its ease of implementation and its
low cost as compared to other temperature measurement techniques.
Experimental
results
obtained
are
verified
by
mathematical equations. They agree with each other.
All temperature and voltage relations can be easily obtained with

World Journal of Science and Technology 2012, 2(4):15-19

the help of microcontroller.

Once the setup is installed it is quiet easy to get results directly.
It is very time saving as values are stored in computers directly.
REFERENCES
[1] Donald F. Adams, Leif A. Carlsson, R. Byron Pipes,
2003.Experimental
Characterization of Advanced Composite
Materials, Third Edition, CRC Press LLC.
[2] L.B Abhang,M.Hameedullah
2010.Chip-tool
interface
temperature prediction model for turning process, International
Journal of Engineering Science and Technology, 2(4) pp. 382393.

19

[3] Herbert E. G., 1926.The measurement of cutting temperatures,

Proceedings of the I Mechanical Engineering (London), 1
pp.289329.
[4] D. OSullivan, M. Cottrell, 2 0 0 1 . Temperature measurement
in single point turning, Journal of Material Processing
Technology, 118,pp. 301308
[5] Kim L. Pickering, Editor, 2008,Properties and Performance of
Natural-fiber Composites, Woodhead Publishing Limited and
CRC Press LLC.
[6] Abdul Hamid Zureich, Alan T. Nettles, 2002. Composite
Materials: Testing, Design and Acceptance Criteria, ASTM
International, USA