Advertisement

On-line estimation of the tool-chip interface temperature field during turning using a sequential inverse method

  • Shuwen Huang
  • Bo Tao
  • Jindang Li
  • Yajun Fan
  • Zhouping Yin
ORIGINAL ARTICLE

Abstract

It is well known that the direct measurement of temperature distribution at the tool-chip interface in a machining process is difficult to accomplish. Thus, this paper provides an on-line inverse technique to estimate the temperature field at the tool-chip interface of a turning tool, using temperatures measured at some sensor-accessible locations. A sequential Tikhonov regularization method (STRM) is proposed to determine the transient heat flux imposed at the tool-chip interface, by solving an inverse heat conduction problem (IHCP). Then, the temperature field at the tool-chip interface is computed by solving the three-dimensional non-linear thermal model, with a method combining Duhamel’s superposition theorem with the finite element method. The procedure proposed shows a superiority in on-line applications due to its high computational efficiency and independence of future measurements. A comparison of the STRM with several other inverse methods in the literature was made through numerical tests. Experimental cutting tests on Ti-6Al-4V titanium alloy were done to validate the thermal model and method. Both numerical and experimental tests show that the proposed method can provide an efficient and easy-to-implement strategy for on-line temperature field monitoring of machine tools.

Keywords

Inverse heat conduction problem On-line tool state monitoring Sequential Tikhonov regularization Tool-chip interface temperature 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Notes

Funding information

The work is supported by the National Natural Science Foundation of China granted under No. 51575215 and U1501248 and the National Basic Research Program of China (973 Program) granted under No. 2013CB035803.

References

  1. 1.
    Jaspers SPFC, Dautzenberg JH, Taminiau DA (1998) Temperature measurement in orthogonal metal cutting. Int J Adv Manuf Technol 14(1):7–12CrossRefGoogle Scholar
  2. 2.
    Le Coz G, Dudzinski D (2014) Temperature variation in the workpiece and in the cutting tool when dry milling Inconel 718. Int J Adv Manuf Technol 74(5–8):1133–1139CrossRefGoogle Scholar
  3. 3.
    Grzesik W (1999) Experimental investigation of the cutting temperature when turning with coated indexable inserts. Int J Mach Tools Manuf 39:355–369CrossRefGoogle Scholar
  4. 4.
    Kaminise AK, Guimarães G, da Silva MB (2014) Development of a tool-work thermocouple calibration system with physical compensation to study the influence of tool-holder material on cutting temperature in machining. Int J Adv Manuf Technol 73(5–8):735–747CrossRefGoogle Scholar
  5. 5.
    Artozoul J, Lescalier C, Bomont O, Dudzinski D (2014) Extended infrared thermography applied to orthogonal cutting: mechanical and thermal aspects. Appl Thermal Eng 64(1–2):441–452CrossRefGoogle Scholar
  6. 6.
    M'Saoubi R, Chandrasekaran H (2011) Experimental study and modelling of tool temperature distribution in orthogonal cutting of AISI 316L and AISI 3115 steels. Int J Adv Manuf Technol 56(9–12):865–877CrossRefGoogle Scholar
  7. 7.
    Werschmoeller D, Li X, Ehmann K (2012) Measurement of transient tool-internal temperature fields during hard turning by insert-embedded thin film sensors. J Manuf Sci Eng 134(6):061004CrossRefGoogle Scholar
  8. 8.
    Abukhshim NA, Mativenga PT, Sheikh MA (2006) Heat generation and temperature prediction in metal cutting: a review and implications for high speed machining. Int J Mach Tools Manuf 46(7–8):782–800CrossRefGoogle Scholar
  9. 9.
    Loewen EG (1954) On the analysis of cutting-tool temperatures. Trans ASME 76:217Google Scholar
  10. 10.
    Zhang J, Liu Z, Du J (2017) Prediction of cutting temperature distributions on rake face of coated cutting tools. Int J Adv Manuf Technol 91(1–4):49–57CrossRefGoogle Scholar
  11. 11.
    Li B, Li H, Liu J, Jia G (2017) An experimental and numerical investigation of temperature distribution on the ceramic cutting tool. Int J Adv Manuf Technol 92(9–12):4221–4230CrossRefGoogle Scholar
  12. 12.
    Puls H, Klocke F, Veselovac D (2016) FEM-based prediction of heat partition in dry metal cutting of AISI 1045. Int J Adv Manuf Technol 86(1–4):737–745CrossRefGoogle Scholar
  13. 13.
    Zhang Y, Gu Y, Chen JT (2010) Boundary element analysis of the thermal behaviour in thin-coated cutting tools. Eng Anal Bound Elem 34(9):775–784MathSciNetCrossRefzbMATHGoogle Scholar
  14. 14.
    Beck JV, Blcakwell B, Clair SR (1985) Inverse heat conduction problems: ill-posed problems. Wiley, New YorkzbMATHGoogle Scholar
  15. 15.
    Yen DW, Wright PK (1986) A remote temperature sensing technique for estimating the cutting interface temperature distribution. J Eng Ind 108(4):252–263CrossRefGoogle Scholar
  16. 16.
    Stephenson DA (1991) An inverse method for investigating deformation zone temperatures in metal cutting. J Eng Ind 113(2):129–136MathSciNetCrossRefGoogle Scholar
  17. 17.
    Kwon P, Schiemann T, Kountanya R (2001) An inverse estimation scheme to measure steady-state tool-chip interface temperatures using an infrared camera. Int J Mach Tools Manuf 41:1015–1030CrossRefGoogle Scholar
  18. 18.
    Lavisse B, Lefebvre A, Sinot O, Henrion E, Lemarié S, Tidu A (2017) Grinding heat flux distribution by an inverse heat transfer method with a foil/workpiece thermocouple under oil lubrication. Int J Adv Manuf Technol 92(5–8):2867–2880CrossRefGoogle Scholar
  19. 19.
    Carvalho SR, Lima e Silva SMM, Machadoa AR, Guimar G (2006) Temperature determination at the chip-tool interface using an inverse thermal model considering the tool and tool holder. J Mater Process Technol 179:97–104CrossRefGoogle Scholar
  20. 20.
    Huang CH, Lo HC (2005) A three-dimensional inverse problem in predicting the heat fluxes distribution in the cutting tools. Numer Heat TR A-Appl 48(10):1009–1034CrossRefGoogle Scholar
  21. 21.
    Liang L, Quan YM, Ke ZY (2011) Investigation of tool-chip interface temperature in dry turning assisted by heat pipe cooling. Int J Adv Manuf Technol 54(1–4):35–43CrossRefGoogle Scholar
  22. 22.
    Liang L, Xu H, Ke Z (2013) An improved three-dimensional inverse heat conduction procedure to determine the tool-chip interface temperature in dry turning. Int J Therm Sci 64:152–161CrossRefGoogle Scholar
  23. 23.
    Wei B, Tan G, Yin N, Gao L, Li G (2016) Research on inverse problems of heat flux and simulation of transient temperature field in high-speed milling. Int J Adv Manuf Technol 84(9–12):2067–2078CrossRefGoogle Scholar
  24. 24.
    Feng Y, Zheng L, Wang M, Wang B, Hou J, Yuan T (2015) Research on cutting temperature of work-piece in milling process based on WPSO. Int J Adv Manuf Technol 79(1–4):427–435CrossRefGoogle Scholar
  25. 25.
    Norouzifard V, Hamedi M (2014) A three-dimensional heat conduction inverse procedure to investigate tool-chip thermal interaction in machining process. Int J Adv Manuf Technol 74(9–12):1637–1648CrossRefGoogle Scholar
  26. 26.
    Brito RF, Carvalho SR, Lima e Silva SMM (2015) Experimental investigation of thermal aspects in a cutting tool using comsol and inverse problem. Appl Thermal Eng 86:60–68CrossRefGoogle Scholar
  27. 27.
    Chen WC, Tsao CC, Liang PW (1997) Determination of temperature distributions on the rake face of cutting tools using a remote method. Int Comm Heat Mass Transfer 24(2):161–170CrossRefGoogle Scholar
  28. 28.
    Samadi F, Kowsary F, Sarchami A (2012) Estimation of heat flux imposed on the rake face of a cutting tool: a nonlinear, complex geometry inverse heat conduction case study. Int Comm Heat Mass Transfer 39(2):298–303CrossRefGoogle Scholar
  29. 29.
    Battaglia J-L, Kusiak A (2005) Estimation of heat fluxes during high-speed drilling. Int J Adv Manuf Technol 26(7–8):750–758CrossRefGoogle Scholar
  30. 30.
    Mondelin A, Valiorgue F, Feulvarch E, Rech J, Coret M (2013) Calibration of the insert/tool holder thermal contact resistance in stationary 3D turning. Appl Thermal Eng 55(1–2):17–25CrossRefGoogle Scholar
  31. 31.
    Woodbury K (2003) Inverse engineering handbook. Press, CRCzbMATHGoogle Scholar

Copyright information

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

Authors and Affiliations

  • Shuwen Huang
    • 1
  • Bo Tao
    • 1
  • Jindang Li
    • 1
  • Yajun Fan
    • 1
  • Zhouping Yin
    • 1
  1. 1.State Key Laboratory of Digital Manufacturing Equipment and TechnologyHuazhong University of Science and TechnologyWuhanPeople’s Republic of China

Personalised recommendations