Research on Cutting-Temperature Field and Distribution of Heat Rates among a Workpiece, Cutter, and Chip for High-Speed Cutting Based on Analytical and Numerical Methods
High-speed cutting is widely employed in aerospace,
 automotive, die, and other industries. However,
 no comprehensive mechanism of highspeed
 cutting behavior was as yet comprehended
 completely. Models of thermal sources and fields
 of cutting temperature ar...
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| Опубліковано в: : | Проблемы прочности |
|---|---|
| Дата: | 2014 |
| Автори: | , , , |
| Формат: | Стаття |
| Мова: | Англійська |
| Опубліковано: |
Інститут проблем міцності ім. Г.С. Писаренко НАН України
2014
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| Онлайн доступ: | https://nasplib.isofts.kiev.ua/handle/123456789/112706 |
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| Назва журналу: | Digital Library of Periodicals of National Academy of Sciences of Ukraine |
| Цитувати: | Research on Cutting-Temperature Field and Distribution of Heat Rates among a Workpiece, Cutter, and Chip for High-Speed Cutting Based on Analytical and Numerical Methods / H.P. An, Z.V. Rui, R.F. Wang, Z.M. Zhang // Проблемы прочности. — 2014. — № 2. — С. 164-171. — Бібліогр.: 11 назв. — англ. |
Репозитарії
Digital Library of Periodicals of National Academy of Sciences of Ukraine| _version_ | 1860222582086696960 |
|---|---|
| author | An, H.P. Rui, Z.V. Wang, R.F. Zhang, Z.M. |
| author_facet | An, H.P. Rui, Z.V. Wang, R.F. Zhang, Z.M. |
| citation_txt | Research on Cutting-Temperature Field and Distribution of Heat Rates among a Workpiece, Cutter, and Chip for High-Speed Cutting Based on Analytical and Numerical Methods / H.P. An, Z.V. Rui, R.F. Wang, Z.M. Zhang // Проблемы прочности. — 2014. — № 2. — С. 164-171. — Бібліогр.: 11 назв. — англ. |
| collection | DSpace DC |
| container_title | Проблемы прочности |
| description | High-speed cutting is widely employed in aerospace,
automotive, die, and other industries. However,
no comprehensive mechanism of highspeed
cutting behavior was as yet comprehended
completely. Models of thermal sources and fields
of cutting temperature are proposed for analysis
of thermal equilibrium between heat generation
and energy consumption at high-speed dry cutting.
Mathematic models of cutting temperature
for three cutting deformation areas are developed
to analyze heat generation and release behavior
in high-speed machining. The ratios of heat distribution
among a chip, cutter and workpiece were
found for different cutting speeds using the
MATLAB software.
Высокоскоростное резание широко используется в авиакосмической, автомобильной и других
отраслях промышленности. Однако комплексный механизм процесса высокоскоростного резания еще недостаточно изучен. На основе анализа теплового равновесия между тепловыделением и потреблением энергии при высокоскоростной обработке без смазочно-охлаждающей
жидкости предложены модели тепловых источников и полей температур резания. Для
анализа влияния выделения и выхода тепла при обработке на высоких скоростях резания
выведены математические модели температур резания для трех зон деформирования. Определены соотношения распределения тепла между стружкой, резаком и заготовкой, иллюстрирующие степень пропорциональности со скоростью с помощью пакета прикладных программ MATLAB.
Високошвидкісне різання широко використовується в авіакосмічній, автомобільній
та інших галузях промисловості. Однак комплексний механізм процесу високошвидкісного різання ще недостатньо вивчений. На основі аналізу теплової рівноваги між
тепловиділенням і споживанням енергії при високошвидкісній обробці без мастильно-охолоджуючої рідини запропоновано моделі теплових джерел та полів температур
різання. Для аналізу впливу виділення і виходу тепла при обробці на високих
швидкостях різання виведено математичні моделі температур різання для трьох зон
деформування. Визначено співвідношення розподілу тепла між стружкою, різаком і
заготівкою, що ілюструють ступінь пропорційності зі швидкістю за допомогою
пакета прикладних програм MATLAB.
|
| first_indexed | 2025-12-07T18:18:24Z |
| format | Article |
| fulltext |
UDC 539.4
Research on Cutting-Temperature Field and Distribution of Heat Rates
among a Workpiece, Cutter, and Chip for High-Speed Cutting Based on
Analytical and Numerical Methods
H. P. An,
a,1
Z. Y. Rui,
b,2
R. F. Wang,
c,3
and Z. M. Zhang
c,4
a Institute for Mechanic Inspection and Fault Diagnosis, Lanzhou City University, Lanzhou, China
b College of Mechano-Electronic Engineering, Lanzhou University of Technology, Lanzhou, China
c Lanzhou Jiao tong University, Lanzhou, China
1 ahp2004@126.com
2 Zhiy_rui@163.com
3 Wangruifeng0808@163.com
4 Zhangzhimei65@126.com
ÓÄÊ 539.4
Èññëåäîâàíèå ïîëÿ òåìïåðàòóð ðåçàíèÿ è ðàñïðåäåëåíèÿ óäåëüíîãî ðàñõîäà
òåïëà ìåæäó çàãîòîâêîé, ðåçàêîì è ñòðóæêîé ïðè âûñîêîñêîðîñòíîì
ðåçàíèè íà îñíîâå àíàëèòè÷åñêèõ è ÷èñëåííûõ ìåòîäîâ
Õ. Ï. Àí
à
, Äæ. Þ. Ðóè
á
, Ð. Ô. Âàíã
â
, Äæ. Ì. Äæàíã
â
à Èíñòèòóò ìåõàíè÷åñêîãî êîíòðîëÿ è äèàãíîñòèêè íåèñïðàâíîñòåé, Óíèâåðñèòåò Ëàíü÷æîó,
Ëàíü÷æîó, Êèòàé
á Ôàêóëüòåò ìåõàíè÷åñêîé è ýëåêòðîííîé òåõíèêè, Óíèâåðñèòåò Ëàíü÷æîó, Ëàíü÷æîó, Êèòàé
â Óíèâåðñèòåò Ëàíü÷æîó Æàî òîíãà, Ëàíü÷æîó, Êèòàé
Âûñîêîñêîðîñòíîå ðåçàíèå øèðîêî èñïîëüçóåòñÿ â àâèàêîñìè÷åñêîé, àâòîìîáèëüíîé è äðóãèõ
îòðàñëÿõ ïðîìûøëåííîñòè. Îäíàêî êîìïëåêñíûé ìåõàíèçì ïðîöåññà âûñîêîñêîðîñòíîãî ðåçà-
íèÿ åùå íåäîñòàòî÷íî èçó÷åí. Íà îñíîâå àíàëèçà òåïëîâîãî ðàâíîâåñèÿ ìåæäó òåïëîâûäåëå-
íèåì è ïîòðåáëåíèåì ýíåðãèè ïðè âûñîêîñêîðîñòíîé îáðàáîòêå áåç ñìàçî÷íî-îõëàæäàþùåé
æèäêîñòè ïðåäëîæåíû ìîäåëè òåïëîâûõ èñòî÷íèêîâ è ïîëåé òåìïåðàòóð ðåçàíèÿ. Äëÿ
àíàëèçà âëèÿíèÿ âûäåëåíèÿ è âûõîäà òåïëà ïðè îáðàáîòêå íà âûñîêèõ ñêîðîñòÿõ ðåçàíèÿ
âûâåäåíû ìàòåìàòè÷åñêèå ìîäåëè òåìïåðàòóð ðåçàíèÿ äëÿ òðåõ çîí äåôîðìèðîâàíèÿ. Îïðå-
äåëåíû ñîîòíîøåíèÿ ðàñïðåäåëåíèÿ òåïëà ìåæäó ñòðóæêîé, ðåçàêîì è çàãîòîâêîé, èëëþñò-
ðèðóþùèå ñòåïåíü ïðîïîðöèîíàëüíîñòè ñî ñêîðîñòüþ ñ ïîìîùüþ ïàêåòà ïðèêëàäíûõ ïðî-
ãðàìì MATLAB.
Êëþ÷åâûå ñëîâà: âûñîêîñêîðîñòíîå ðåçàíèå áåç ñìàçî÷íî-îõëàæäàþùåé æèäêîñòè,
ïîëå òåìïåðàòóð, ðàñïðåäåëåíèå òåïëà, âûäåëÿþùåãîñÿ ïðè ðåçàíèè, àíàëèòè÷åñêèé
ìåòîä.
Introduction. Cutting heat is a kind of important physical phenomenon during the
metal-cutting process, which implies a temperature increment in the cutting area. This
temperature and its distribution can affect the cutting forces, chip deformation, tool wear,
and finished surface quality. For the particular cutting conditions, the temperature depends
on cutting speed. The major part of energy spent during high-speed cutting (HSC) is
converted into heat energy, with a small share being stored in the deformed materials [1–3].
© H. P. AN, Z. Y. RUI, R. F. WANG, Z. M. ZHANG, 2014
164 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2014, ¹ 2
Friction power dissipation almost fully turns into a heat energy and enhance the
temperature rise. However, the effect of HSC is different from that of general cutting. As
compared to general cutting, HSC has a lower temperature and smaller cutting forces [4, 5].
Thus, it is very important for comprehension of the tool wear mechanism to study the
temperature field and distribution rates of heat transferred to a workpiece, cutter and chip
under dry-cutting conditions. In general, the temperature field can be obtained by
experimental methods, numerical simulation, and mathematical analysis. Experimental
methods can provide the approximate temperature values by surveying specific points on
tool or/and workpiece in course of machining, but this would require much time and cost.
Numerical simulation is useful to solve nonlinear heat conduction problems or partial
differential equations for objects having complicated shapes and boundary conditions [6,
7]. The machining course can be imitated by the use of some simulation software, while
some appropriate mathematical models and cutting tests are required to estimate the errors.
Mathematical analysis is applied to deal with linear problems or few nonlinear heat
conduction objects of simple geometry, but the veracity of the results obtained is hard to be
estimated. The heat source method is a way to solve various heat conduction problems via
some temperature formulas using an integral method for a dotted heat source located in an
imaginary infinite heat conductor plane, which can yield a simple and approximately
correct answer. We propose a heat conduction model by the analysis of laws of heat
generation and spreading from cutting pattern, in which the average temperature of the
cutting area can be obtained by combining the heat source method with an analytical
technique. Moreover, some distributions rates (R1 and R3) of cutting heat with cutting
speed increment are calculated using the MATLAB software.
Heat Source and Model of Heat Conduction for Cutting. For energy dissipation to
undergo elastic-plastic deformation and frictional work during metal cutting processes, the
formed chips from plastic-deformation work consumed in the material shear slip are
dominant, while frictional work values corresponding to domains between the rake face of
cutter and the chip underside, as well as the back face of cutter and machined face, are
relative low. The schematic diagram for the model of three cutting-heat sources is
illustrated by Fig. 1.
The total power consumption of HSC, containing the energy (Wn ) consumed in
forming new surface of chip bottom and interface energy of work surface can be neglected,
as compared to the total energy consumption, because it is very low. The deformation
energy (Ws) in the shear zone is large, and frictional work (W f ) from rake face of cutter and
bottom of chip, as well as the back surface of cutter and finished surface of workpiece, is
smaller than Ws , while the wasted power (Wn ) is negligible due to instant change of shear
slipping in the cutting material. Suppose that A1 , A2 , and A3 are the areas of shear
surface, cutter–chip contact, and cutter–workpiece contact, respectively. Accordingly, q1,
q2 , and q3 represent the heat quantities produced for the three zones per unit time interval
and unit area. Then, we have
Q q A q A q A� � �1 1 2 2 3 3 , (1)
Research on Cutting-Temperature Field and Distribution of Heat Rates ...
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2014, ¹ 2 165
Fig. 1. Heat source of cutting and their models of heat conduction.
where Q represents the total energy produced per unit time and unit area, q1 is a heat flux
due to power dissipation of shear deformation, q F v A vs s c s s1 � �( csc )� � [J/(s m� 2)], in
which � is shear angle (deg), Fs is shear force (N), vs is shear slipping speed (m/s), Ac
is section area of cutting layer (m2), A a ac c w� , ac is thickness of cutting layer (m), � s
is shear stress (Pa), q2 is heat flux transformed from frictional work between cutter and
chip interface [J/(s m� 2)], q F v l af c f w2 1� ( ), F f 1 is frictional force (N), vc is sliding
speed of chip along the cutter rake face (m/s), l f is length of cutter-chip contact (m), aw
is width of cutting layer (m), q3 is heat flux converted by frictional work between cutter
and workpiece [J/(s m� 2)], q F v l af w w3 � ( ), F f is frictional force between cutter and
workpiece (N), v is cutting speed (m/s), and lw is length of contact between the back
surface of cutter and workpiece (m).
Factors affecting heat conduction are as follows.
1. Character of heat conduction of workpiece material. Higher the heat conductivity
coefficient, higher the value of heat flowing into the workpiece and chip per unit time.
Lower the temperature in cutting area, less the cutter wear, but cutting temperature rise
leads to thermal deformation of the machined workpiece. Moreover, a high temperature in
the cutting area results in oxidation – or/and diffusion of the cutter area.
2. Character of heat conduction of the tool material. A higher coefficient of heat
conduction of tool material implies a higher heat energy spread into the tool per unit time,
which results in a less temperature rise in the cutting area and less tool wear, and thus in
prolongation of the tool life.
3. Impact of surrounding medium. An efficient coolant can take away a lot of cutting
heat and slow down the tool wear process.
4. Time of tool-workpiece interaction. HSC makes chips splash quickly and remove a
lot of cutting heat, which tends to lower temperature values in the cutting zone.
Field of Cutting Temperature. Field of cutting temperature is a distribution of
temperature in the cutting zone. The temperature field of HSC consists of zone of shear
deformation, frictional portion of rake face of tool to chip and tool-workpiece flank surface.
Average Temperature of Shear Plan. The cut layers in a workpiece turn into chips by
shear deformation under squeezing action of a tool. The major part of energy consumed in
shear deformation is transformed into the heat energy under the dry-cutting conditions,
some part of which is conducted to chips and the part is transferred to the workpiece.
Assume that R1 is the share of heat transferred to a chip. Thus, per unit time interval, heat
energy values corresponding to chips and workpieces are R q a ac w1 1 sin � and
( ) sin ,1 1 1� R q a ac w � respectively. Without regard of heat convection into air, the average
temperature rise in the shear plane under the action of heat value R q a ac w1 1 sin � can be
expressed as
�T
R q a a
c va a
R q
c v
s
c w
c w
� �
1 1
1 1
1 1
1 1
sin
sin
,
�
�
(2)
where �Ts is the average temperature rise in the shear plane (
C), c1 is specific heat for
the average temperature of ( ~ )T Ts0 in the workpiece material [J/(kg C�
)], and 1 is
density of the workpiece material (kg/m3).
Suppose that T0 is the initial temperature of workpiece, then the chip average
temperature in the shear plane can be given by
T T T T
R q
c v
s s� � � �0 0
1 1
1 1
�
�sin
, (3)
where Ts is the average temperature in the shear plane.
H. P. An, Z. Y. Rui, R. F. Wang, and Z. M. Zhang
166 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2014, ¹ 2
According to the computing method of average temperature caused by a moving
dotted heat source in a semi-infinite object [8–11], the average temperature in the shear
plane corresponding to the heat introduced into the workpiece can be obtained as follows:
�� �
� �
T T
R q a a
v
s
c
0
1 1
1
1 0
0
0 754
1
.
( ) cos( )
sin cos
,
�
�
�
(4)
where �1 is heat conductivity of the workpiece material at the average temperature for
( ~ )T Ts0 � [W/(m C�
)], and a1 is thermal diffusivity of the workpiece material at
temperature (T Ts0 ~ � ) (m2/s).
A narrow shear plane can be considered as a face heat source, that is T Ts s� �. Also
consider that thermal diffusivity a c1 1 1 1� � , while relative slippage of the shear plane
�
� �
� �cos (sin cos( )).0 0 From Eqs. (3) and (4), the folowing relation can be obtained
R
va a
va a a
va
c
c
c
1
1
1 1
0 754
1 0 754
1
1 1 3263
�
�
�
�
. ( )
. ( )
.
.
�
� �
(5)
Equation (5) shows that the ratio (R1) of heat distribution to chip increases with the
increment of cutting speed (v) or/and thickness (ac ) of the cutting layer. It means that much
more heat is carried away by chips, and less heat is conducted to the workpiece, especially
in HSC. With reduction of thermal diffusivity (a1) and relative slippage (�), chips take more
quantity of heat, which depends on the properties of the workpiece material. The
experimental results prove that the removed chips take away a lot of heat at HSC, which
leads to a low cutting temperature and reduction of thermal deformation effect on
machining precision. Insofar as difficult-to-process materials have a low thermal diffusivity,
and the cutting heat is not easy to be spread away, this results in a cutting temperature rise
and intensifies the cutter wear and tear, thus shortening the cutter life. Therefore, in order to
improve the processing quality and tool life in HSC, an appropriate choice of workpiece
and cutter materials is necessary. In addition to this, reasonable cutting parameters are
demanded. Numerous HSC tests for specific materials can be used for corroboration of the
calculated results and further optimization. Obtaining the particular values of R1 via
experiments and substituting them into Eq. (4), one can acquire the average temperature
(Ts) in the shear plane.
Average Temperature of Cutter Rake Face. A part of heat (Q2) produced by friction
between the cutter and the chip flows into the chip and the other part – into the cutter.
Assume that R2 is the ratio of heat value corresponding to the chip, then the heat values
related to the chip and the cutter are R q l af w2 2 and ( ) ,1 2 2� R q l af w respectively. In the
course of cutting, the rub heat source of the cutter-to chip contact surface keeps moving
along the cutter surface from the start to the end, while the chip runs off continuously. This
is equivalent to a fixed heat source moving in an infinite plane. Then, the rise in the
average temperature of the chip bottom face is
�T
R q
c
l
a v
f
f
1
2 2
2 2 2
0 754
�
.
,
�
(6)
where �T f 1 is the average temperature rise (
C), 2 is density of the workpiece material
(kg/m3), c2 is specific heat value for the average temperature T T Ts s f~ ( )� [J/(kg C�
)],
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2014, ¹ 2 167
Research on Cutting-Temperature Field and Distribution of Heat Rates ...
a2 is thermal diffusivity of the workpiece material for temperature T Ts f� (m2/s), and � is
deformation coefficient. The average temperature in the chip rub area is
T T T T
R q
c
l
a v
f s f s
f
� � � �� 1
2 2
2 2 2
0 754.
.
�
(7)
With regard to the cutter, ( )1 2 2� R q refers to the fixed heat source, which implies
the average temperature of the cutter rake face as follows:
T
R q l
A Tt
f
t
t t�
�
�
( )
,
1 2 2
0
�
(8)
where � t is heat conductivity of the tool material at temperature of Tt [W/(m C�
)], T t0 is
the initial temperature of the cutter (
C), and At is coefficient of length-to width ratio
related to the heat source area. Both T f and Tt are the average temperatures of the
cutter-to-chip contact area, which should be equal. In view of v vc � � , we obtain R2 by
combination of Eqs. (7) and (8)
R
q l A
T T
q
c
l
va
q l A
F vAf t
t
t s
f f t
t
f
2
2
0
2
2 2 2
2
1
0 754
�
� �
�
�
�
�
�
.
t
w t
t s
f
f w
f f t
w t
a
T T
F v
l a c
l
va
F vA
a
��
�
�
��
� �
�
0
1
2 2 2
10 754.
. (9)
From formula (9), it can be seen that heat fluxes from the cutter-to-chip heat source to
the chip are affected by many factors and are coupled with the heat flux from the shear
plane to the chip. This coupling/interaction relates to the cutting speed and frictional
conditions for the given cutting conditions. For the equal values of the tool and workpiece
initial temperatures, Eq. (9) can be reduced to
R
A a c a vat t s w c
2
0 1 1 11 1 3263
�
� �( ) cos [( . ( )) sin cos�� �
� � ( ) ]
. ( ) ( )
.
�
� ��
0 1
2 2 20 754
�
�
F
c vl a A
f
f t t
(10)
Equation (10) indicates that heat value related to a chip increases with cutting speed.
Average Temperature in the Machined Surface-Tool Flank Surface Contact Area.
In the course of steady cutting, a part of heat is produced by sliding friction between the
cutter flank surface and the workpiece machined surface, and it is distributed between the
tool and the workpiece. Assume that the share/ratio of heat dissipated into the cutter is R3,
then the heat fluxes into the cutter and workpiece are R q3 3 and ( )1 3 3� R q , respectively.
The rub heat source along the workpiece is a moving one. The temperature of the machined
surface caused by heat dissipation ( )1 3 3� R q can be expressed as
T
R q l
c
a
vl
Ttw
w
w
�
�
�0 754
1 3 3
3 3
3
0.
( )
,
(11)
where a3 is thermal diffusivity of the workpiece material at temperature Ttw (m2/s), 3
is mass density of the workpiece material (kg/m3), and c3 is specific heat of the workpiece
material [J/(kg C�
)].
168 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2014, ¹ 2
H. P. An, Z. Y. Rui, R. F. Wang, and Z. M. Zhang
The rub heat source to the cutter flank surfac can be taken as a fixed heat source, as
well. The average temperature of the contact area at the tool back surface is equal to
T
R q l
A Twt
w
t
w� �
3 3
0
�
, (12)
where � t is heat conductivity of the workpiece material [W/(m C�
)], Aw is form factor
related to the heat source size ratio a lw w . Similarly to the cutter rake face, R3 can be
obtained from Eqs. (11) and (12) as
R
q l
c
a
vl
q l
c
a
vl
q l
w
w
w
w
w
t
3
3
3 3
3
3
3 3
3 3
0 754
0 754
1
1
�
�
�
�
.
.
�
1 3263
3 3
3
.
.
�
c vl
at
w
(13)
From formula (13), it can be seen that the ratio of heat distribution for the tool
manifests a significant reduction with cutting speed. After obtaining R3 for the given
cutting condition, it is easy to find the average temperature at the machined surface of the
workpiece or at the cutter flank surface via Eq. (11) or Eq. (12).
Visualization of Heat Distribution. In order to derive the particular ratios of heat
distribution between chip, workpiece and cutter in the cutting temperature fields for
particular materials, caclulations were made for the cutting medium carbon steel and
ceramic cutting tool, whose physical parameters are given Table 1. The calculated heat
distributions for the first and the third deformation zones are shown in Figs. 2 and 3, which
illustrate the numerical expressions in Eqs. (5) and (13). It can be seen from Figs. 2 and 3
that the ratios of R1 and R3 vary with cutting speed.
Figure 2 shows that share of the energy consumed in shear deformation and
dissipated in a chip (ratio R1) increases with cutting speed. One can see that this ratio
manifests a steep rise depicted by a straight line at low velocity, followed by less steep rise
at the medium speed and saturation portion at high speed. Finally, it attains a constant
value, which can be attributed to the fact that heat produced by shear deformation is carried
away by rapidly flowing chips. As a consequence, less heat is dissipated in the workpiece.
From Fig. 2, it can also be found that 96.24% of heat is carried away by the chip – at high
speed. The simulated results imply that HSC is not only benefitial for the work efficiency
but also makes it possible to reduce the cutting heat effect on the machining quality, which
is confirmed by the available experimental results on the HSC. Thus, Fig. 2 can be used to
design the cutting parameters for a workpiece with the required precision level and to
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2014, ¹ 2 169
Research on Cutting-Temperature Field and Distribution of Heat Rates ...
T a b l e 1
Physical Parameters of Cutter and Workpiece Materials
Materila
Workpiece Tool
Medium carbon steel Al2O3 ceramic
Density
3 , kg/m3
Heat capacity
c3 , J/(kg C�
)
Heat conductivity
�t , W/(kg C�
)
7850 480 38.2
optimize the cutting conditions. For example, by determination of the cutting speed
according to the accuracy requirements and heat transfer ratios, one can get robust evidence
to establish the optimal HSC processing plans.
The heat distribution in the cutter depicted in Fig. 3 indicates that the heat ratio
corresponding to the interface between a cutter and a machined surface is very small. This
value is higher at low cutting speed for the given cutting conditions and is sharply reduced
with cutting speed. This ratio in the third deformation zone (in the tool) is also very low,
since under high-speed conditions there is not enough time for heat to dissipate into the
tool, so the ratio (R3) of heat in the tool is very low. With increase in the cutting speed, time
of heat conduction decreases sharply and it is too late for the rub heat to be transfered to the
tool. The above statements show that wear and tear of the cutting tool flank surface is
limited by the rub heat, which can supply a reference for research on tool wear mechanisms.
Conclusions. This paper ascertains heat sources of metal cutting by means of analysis
of the energy consumption in three deformation zones for dry cutting. Models of heat
generation are proposed and heat-conduction laws based on the energy from cutting
deformation and frictional work at steady cutting. By using the average temperature
computation of a moving heat source in a semi-infinite plane, one obtains the average
temperatures in the shear plane and cutter rake face, with disregard of the cutter flank
surface. This also provides distribution rates of the three heat sources for the chip, cutter
and workpiece. Qualitative analysis for three deformation zones and quantitative visualization
for heat distribution ratios of the first and third deformation zones have been validated by
some experimental results.
1. The ratio of heat energy which is dissipated in a chip in the first deformation zone
increases with cutting speed, increasing fastest at low speed, slower at intermediate speed,
and then remains a constant value with the slowest increment at HSC. These results
indicate that the HSC is advantageous to improve the processing efficiency and work
accuracy.
2. The ratio of rub heat dissipated in a chip in the second deformation zone can
increase with cutting speed, in which it reacts continuously with heat from the first
deformation. Due to many complex influencing factors, this needs a further analytical
investigation for the actual HSC conditions.
3. The ratio of rub heat dissipated in a tool in the third deformation is reduced with
cutting speed, while this ratio descends fastest at low speed, slower at intermediate speed,
170 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2014, ¹ 2
H. P. An, Z. Y. Rui, R. F. Wang, and Z. M. Zhang
Fig. 2 Fig. 3
Fig. 2. Rate of heat distribution in a chip for the first deformation zone.
Fig. 3. Rate of heat distribution in a cutter for the third deformation zone.
and very slowly at high speed. For the given cutting conditions, R3 1~ ‰, which can offer
a reference for studying the wear mechanism of flank surface of cutting tool at the HSC.
4. The acquired cutting-temperature-field model is applied to predict temperature of
the shear plane, rake face and flank surface of a cutter and is instrumental for refining the
HSC mechanism by the comparative analysis with the experimental results.
Acknowledgements. The support of this study by National Nature Science Foundation
of China under Grant No. 51065014 and Postgraduate Tutors Scientific Research Project of
Gan Su Province Education Department, China under Grant No. 1212-205 is greatly
appreciated.
Ð å ç þ ì å
Âèñîêîøâèäê³ñíå ð³çàííÿ øèðîêî âèêîðèñòîâóºòüñÿ â àâ³àêîñì³÷í³é, àâòîìîá³ëüí³é
òà ³íøèõ ãàëóçÿõ ïðîìèñëîâîñò³. Îäíàê êîìïëåêñíèé ìåõàí³çì ïðîöåñó âèñîêîøâèä-
ê³ñíîãî ð³çàííÿ ùå íåäîñòàòíüî âèâ÷åíèé. Íà îñíîâ³ àíàë³çó òåïëîâî¿ ð³âíîâàãè ì³æ
òåïëîâèä³ëåííÿì ³ ñïîæèâàííÿì åíåð㳿 ïðè âèñîêîøâèäê³ñí³é îáðîáö³ áåç ìàñòèëü-
íî-îõîëîäæóþ÷î¿ ð³äèíè çàïðîïîíîâàíî ìîäåë³ òåïëîâèõ äæåðåë òà ïîë³â òåìïåðàòóð
ð³çàííÿ. Äëÿ àíàë³çó âïëèâó âèä³ëåííÿ ³ âèõîäó òåïëà ïðè îáðîáö³ íà âèñîêèõ
øâèäêîñòÿõ ð³çàííÿ âèâåäåíî ìàòåìàòè÷í³ ìîäåë³ òåìïåðàòóð ð³çàííÿ äëÿ òðüîõ çîí
äåôîðìóâàííÿ. Âèçíà÷åíî ñï³ââ³äíîøåííÿ ðîçïîä³ëó òåïëà ì³æ ñòðóæêîþ, ð³çàêîì ³
çàãîò³âêîþ, ùî ³ëþñòðóþòü ñòóï³íü ïðîïîðö³éíîñò³ ç³ øâèäê³ñòþ çà äîïîìîãîþ
ïàêåòà ïðèêëàäíèõ ïðîãðàì MATLAB.
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Received 22. 11. 2013
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2014, ¹ 2 171
Research on Cutting-Temperature Field and Distribution of Heat Rates ...
|
| id | nasplib_isofts_kiev_ua-123456789-112706 |
| institution | Digital Library of Periodicals of National Academy of Sciences of Ukraine |
| issn | 0556-171X |
| language | English |
| last_indexed | 2025-12-07T18:18:24Z |
| publishDate | 2014 |
| publisher | Інститут проблем міцності ім. Г.С. Писаренко НАН України |
| record_format | dspace |
| spelling | An, H.P. Rui, Z.V. Wang, R.F. Zhang, Z.M. 2017-01-26T18:31:49Z 2017-01-26T18:31:49Z 2014 Research on Cutting-Temperature Field and Distribution of Heat Rates among a Workpiece, Cutter, and Chip for High-Speed Cutting Based on Analytical and Numerical Methods / H.P. An, Z.V. Rui, R.F. Wang, Z.M. Zhang // Проблемы прочности. — 2014. — № 2. — С. 164-171. — Бібліогр.: 11 назв. — англ. 0556-171X https://nasplib.isofts.kiev.ua/handle/123456789/112706 539.4 High-speed cutting is widely employed in aerospace,
 automotive, die, and other industries. However,
 no comprehensive mechanism of highspeed
 cutting behavior was as yet comprehended
 completely. Models of thermal sources and fields
 of cutting temperature are proposed for analysis
 of thermal equilibrium between heat generation
 and energy consumption at high-speed dry cutting.
 Mathematic models of cutting temperature
 for three cutting deformation areas are developed
 to analyze heat generation and release behavior
 in high-speed machining. The ratios of heat distribution
 among a chip, cutter and workpiece were
 found for different cutting speeds using the
 MATLAB software. Высокоскоростное резание широко используется в авиакосмической, автомобильной и других
 отраслях промышленности. Однако комплексный механизм процесса высокоскоростного резания еще недостаточно изучен. На основе анализа теплового равновесия между тепловыделением и потреблением энергии при высокоскоростной обработке без смазочно-охлаждающей
 жидкости предложены модели тепловых источников и полей температур резания. Для
 анализа влияния выделения и выхода тепла при обработке на высоких скоростях резания
 выведены математические модели температур резания для трех зон деформирования. Определены соотношения распределения тепла между стружкой, резаком и заготовкой, иллюстрирующие степень пропорциональности со скоростью с помощью пакета прикладных программ MATLAB. Високошвидкісне різання широко використовується в авіакосмічній, автомобільній
 та інших галузях промисловості. Однак комплексний механізм процесу високошвидкісного різання ще недостатньо вивчений. На основі аналізу теплової рівноваги між
 тепловиділенням і споживанням енергії при високошвидкісній обробці без мастильно-охолоджуючої рідини запропоновано моделі теплових джерел та полів температур
 різання. Для аналізу впливу виділення і виходу тепла при обробці на високих
 швидкостях різання виведено математичні моделі температур різання для трьох зон
 деформування. Визначено співвідношення розподілу тепла між стружкою, різаком і
 заготівкою, що ілюструють ступінь пропорційності зі швидкістю за допомогою
 пакета прикладних програм MATLAB. The support of this study by National Nature Science Foundation
 of China under Grant No. 51065014 and Postgraduate Tutors Scientific Research Project of
 Gan Su Province Education Department, China under Grant No. 1212-205 is greatly
 appreciated en Інститут проблем міцності ім. Г.С. Писаренко НАН України Проблемы прочности Научно-технический раздел Research on Cutting-Temperature Field and Distribution of Heat Rates among a Workpiece, Cutter, and Chip for High-Speed Cutting Based on Analytical and Numerical Methods Исследование поля температур резания и распределения удельного расхода тепла между заготовкой, резаком и стружкой при высокоскоростном резании на основе аналитических и численных методов Article published earlier |
| spellingShingle | Research on Cutting-Temperature Field and Distribution of Heat Rates among a Workpiece, Cutter, and Chip for High-Speed Cutting Based on Analytical and Numerical Methods An, H.P. Rui, Z.V. Wang, R.F. Zhang, Z.M. Научно-технический раздел |
| title | Research on Cutting-Temperature Field and Distribution of Heat Rates among a Workpiece, Cutter, and Chip for High-Speed Cutting Based on Analytical and Numerical Methods |
| title_alt | Исследование поля температур резания и распределения удельного расхода тепла между заготовкой, резаком и стружкой при высокоскоростном резании на основе аналитических и численных методов |
| title_full | Research on Cutting-Temperature Field and Distribution of Heat Rates among a Workpiece, Cutter, and Chip for High-Speed Cutting Based on Analytical and Numerical Methods |
| title_fullStr | Research on Cutting-Temperature Field and Distribution of Heat Rates among a Workpiece, Cutter, and Chip for High-Speed Cutting Based on Analytical and Numerical Methods |
| title_full_unstemmed | Research on Cutting-Temperature Field and Distribution of Heat Rates among a Workpiece, Cutter, and Chip for High-Speed Cutting Based on Analytical and Numerical Methods |
| title_short | Research on Cutting-Temperature Field and Distribution of Heat Rates among a Workpiece, Cutter, and Chip for High-Speed Cutting Based on Analytical and Numerical Methods |
| title_sort | research on cutting-temperature field and distribution of heat rates among a workpiece, cutter, and chip for high-speed cutting based on analytical and numerical methods |
| topic | Научно-технический раздел |
| topic_facet | Научно-технический раздел |
| url | https://nasplib.isofts.kiev.ua/handle/123456789/112706 |
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