Investigations on tool temperature with heat conduction and heat convection in high-speed slot milling of Ti6Al4V

  • Fulin Jiang
  • Zhanqiang Liu
  • Fazhan Yang
  • Zhaolin Zhong
  • Shufeng Sun
ORIGINAL ARTICLE
  • 6 Downloads

Abstract

Tool temperature has significant effects on tool wear and tool life in high-speed machining. Salomon hypothesized that increasing cutting speeds would make tool temperature rise to a maximum point and decrease after a certain cutting speed. However, the maximum tool temperature at a certain cutting speed in Salomon’s hypothesis has not been fully validated and widely accepted by academic researchers and industrial engineers. In this paper, a series of experiments for slot milling of Ti6Al4V alloy at different cutting speeds are carried out and tool insert temperatures are measured. The experimental results indicate that the slot milling tool temperature increases first and then decreases as the cutting speed grows. The critical cutting speed is 1500 m/min for slot milling of Ti6Al4V. To analyze the experimental results and find reasons for the decreased milling tool temperature at high cutting speed, we propose a tool temperature prediction model for slot milling insert. The effects of heat convection and heat conduction time on slot milling tool temperature are analyzed. The finite element method is applied to simulate the heat flux and tool-chip contact length under different uncut chip thicknesses. The simulated heat flux is included in the proposed tool temperature prediction model. The variation of tool temperature in the milling process is affected by heat generation, heat conduction time, and convection coefficient. This research demonstrates that the maximum tool temperature at a certain cutting speed in Salomon’s hypothesis can be accepted for interrupted machining processes.

Keywords

Cutting speed Tool temperature Heat conduction and convection Slot milling Ti6Al4V 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Notes

Acknowledgements

The authors would like to acknowledge the financial support from the National Natural Science Foundation of China (51425503, 51375272, U1201245). This work was supported by the Taishan Scholar Project of Shandong Province (ts201511038), the Key Grant Technology Project of Shandong Province (2016ZDJS02A15), and Innovation and Entrepreneurial Talent Project of Qingdao City (〔2016〕11).

References

  1. 1.
    Salomon CJ (1931) Process for machining metals of similar acting materials when being worked by cutting tools. German patent, Number 523594Google Scholar
  2. 2.
    Radulescu R, Kapoor SG (1994) An analytical model for prediction of tool temperature fields during continuous and interrupted cutting. ASME J Eng Ind 116:135–143CrossRefGoogle Scholar
  3. 3.
    Chen M, Sun F, Wang H, Yuan R, Qu Z, Zhang S (2003) Experimental research on the dynamic characteristics of the cutting temperature in the process of high-speed milling. J Mater Process Technol 138:468–471CrossRefGoogle Scholar
  4. 4.
    McGee FJ (1979) High speed machining-study methods for aluminum workpieces. Am Mach 123:121–126Google Scholar
  5. 5.
    Dewes RC, Ng E, Chua KS, Newton PG, Aspinwall DK (1999) Temperature measurement when high speed machining hardened mould/die steel. J Mater Process Technol 92-93:293–301CrossRefGoogle Scholar
  6. 6.
    Komanduri R, Flom DG, Lee M (1984) Highlights of the DARPA advanced machining research program. Proceedings of the Winter Annual Meeting of the ASME, New Orleans, December 15-36Google Scholar
  7. 7.
    Longbottom JM, Lanham JD (2006) A review of research related to Salomon’s hypothesis on cutting speeds and temperatures. Int J Mach Tools Manuf 46:1740–1747CrossRefGoogle Scholar
  8. 8.
    Schultz H (1984) High speed milling of aluminium alloys. Proceedings of the Winter Annual Meeting of the ASME, New Orleans, December, 241–244Google Scholar
  9. 9.
    Li L, Chang H, Wang M, Zuo DW, He L (2004) Temperature measurement in high speed milling Ti6Al4V. Key Eng Mater 259-260:804–808CrossRefGoogle Scholar
  10. 10.
    Sasahara H, Kato A, Nakajima H, Yamamoto H, Muraki T, Tsutsumi M (2008) High-speed rotary cutting of difficult-to-cut materials on multitasking lathe. Int J Mach Tools Manuf 48:841–850CrossRefGoogle Scholar
  11. 11.
    Palmai Z (1987) Cutting temperatures in interrupted cutting. Periodica Polytechnica Mechanica 31:61–78Google Scholar
  12. 12.
    Ueda T, Hosokawa A, Oda K, Yamada K (2001) Temperature on flank face of cutting tool in high speed milling. CIRP Ann Manuf Technol 50:37–40CrossRefGoogle Scholar
  13. 13.
    Dagiloke IF, Kaldos A, Douglas S, Mills B (1995) High-speed machining: an approach to process analysis. J Mater Process Technol 54:82–87CrossRefGoogle Scholar
  14. 14.
    Jiang FL, Liu ZQ, Wan Y, Shi ZY (2013) Analytical modeling and experimental investigation of tool and workpiece temperatures for interrupted cutting 1045 steel by inverse heat conduction method. J Mater Process Technol 213:887–894CrossRefGoogle Scholar
  15. 15.
    Yang Y, Zhu YY (2014) Study on cutting temperature during milling of titanium alloy based on FEM and experiment. Int J Adv Manuf Technol 73:1511–1521CrossRefGoogle Scholar
  16. 16.
    Le Coz G, Jrad M, Laheurte P (2017) Analysis of local cutting edge geometry on temperature distribution and surface integrity when dry drilling of aeronautical alloys. Int J Adv Manuf Technol 93(5–8):2037–2044CrossRefGoogle Scholar
  17. 17.
    Mia M, Khan MA, Dhar NR (2017) Performance prediction of high-pressure coolant assisted turning of Ti-6Al-4V. Int J Adv Manuf Technol 90(5–8):1433–1445CrossRefGoogle Scholar
  18. 18.
    Mia M, Khan MA, Dhar NR (2017) High-pressure coolant on flank and rake surfaces of tool in turning of Ti-6Al-4V: investigation on surface roughness and tool wear. Int J Adv Manuf Technol 90(5–8):1825–1834CrossRefGoogle Scholar
  19. 19.
    Liang XL, Liu ZQ (2017) Experimental investigations on effects of tool flank wear on surface integrity during orthogonal dry cutting of Ti-6Al-4V. Int J Adv Manuf Technol 93(5–8):1617–1626CrossRefGoogle Scholar
  20. 20.
    Armendia M, Garay A, Villar A, Davies MA, Arrazola PJ (2010) High bandwidth temperature measurement in interrupted cutting of difficult to machine materials. CIRP Ann Manuf Technol 59:97–100CrossRefGoogle Scholar
  21. 21.
    Stephenson DA, Ali A (1992) Tool temperatures in interrupted metal cutting. ASME J Eng Ind 114:127–136Google Scholar
  22. 22.
    Cui XB, Zhao J, Pei ZQ (2012) Analysis of transient average tool temperatures in face milling. Int Commun Heat Mass Transfer 39:786–791CrossRefGoogle Scholar
  23. 23.
    Loewen EG, Shaw MC (1954) On the analysis of cutting tool temperature. ASME J Eng Ind 76:217–231Google Scholar
  24. 24.
    Johnson GR, Cook WH (1985) Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures. Eng Fract Mech 21:31–48CrossRefGoogle Scholar
  25. 25.
    Krishnaraj V, Samsudeensadham S, Sindhumathi R, Kuppan P (2014) A study on high speed end milling of titanium alloy. Proc Eng 97:251–257CrossRefGoogle Scholar
  26. 26.
    Rao B, Dandekar CR, Shin YC (2011) An experimental and numerical study on the face milling of Ti6Al4V alloy: tool performance and surface integrity. J Mater Process Technol 211:294–304CrossRefGoogle Scholar
  27. 27.
    Sato M, Tamura N, Tanka H (2011) Temperature variation in the cutting tool in end milling. J Manuf Sci Eng 133:021005.1–021005.7CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  • Fulin Jiang
    • 1
    • 2
    • 3
  • Zhanqiang Liu
    • 2
    • 3
  • Fazhan Yang
    • 1
  • Zhaolin Zhong
    • 1
  • Shufeng Sun
    • 1
  1. 1.School of Mechanical EngineeringQingdao University of TechnologyQingdaoPeople’s Republic of China
  2. 2.School of Mechanical EngineeringShandong UniversityJinanPeople’s Republic of China
  3. 3.Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of EducationShandong UniversityJinanPeople’s Republic of China

Personalised recommendations