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THERMAL MODELING & ANALYSIS OF
CARBIDE TOOL USING FINITE ELEMENT
METHOD
A Thesis
Submitted in partial fulfillment of the requirements for the award of degree
of
MASTER OF ENGINEERING
IN
CAD/CAM & ROBOTICS ENGINEERING
Submitted By
Amit Gupta
Roll No. 8038102
Under the supervision of
Mr.Gaurav Bartarya Mr. Ravinder K Duvedi
Lecturer, MED Lecturer, MED
T.I.E.T., Patiala T.I.E.T., Patiala
MECHANICAL ENGINEERING DEPARTMENT
THAPAR INSTITUTE OF ENGINEERING AND TECHNOLOGY
(Deemed University)
PATIALA147004, (INDIA)
June 2005
2
CERTIFICATE
This is to certify that the seminar entitled “ Thermal Modeling & Analysis of Carbide
Tool Using Finite Element Method ”, being submitted by Mr. Amit Gupta in partial
fulfillment of the requirements for the award of the degree of Master of Engineering
(CAD/CAM & Robotics Engineering) at Thapar Institute of Engineering and
Technology (Deemed University), Patiala (INDIA) is a bonafide work carried out by
him under our guidance and supervision and that no part of this thesis has been submitted
for the award of any other degree .
(Mr. Gaurav Bartarya) (Mr. Ravinder Kumar Duvedi)
Lecturer, MED Lecturer, MED
T.I.E.T. Patiala147004(PUNJAB) T.I.E.T. Patiala147004(PUNJAB)
(Dr. S. K. Mohapatra) (Dr. D. S Bawa)
Professor& Head, MED Dean Academic Affairs
T.I.E.T. Patiala147004(PUNJAB) T.I.E.T. Patiala147004(PUNJAB)
3
ACKNOWLEDGEMENT
I express my sincere gratitude to my guide, Mr. Gaurav Bartarya, and Mr.
Ravinder Kumar Duwedi, Mechanical Engineering Department, Thapar Institute of
Engineering & Technology for his valuable guidance, proper advice, and careful
reviews of my work at all stages, and their highly appreciated instruction and constant
encouragement during the course of my work on this thesis.
I am highly thankful to Dr. Vijay Jadon, Asst. Prof., Mechanical Engineering
Department, Thapar Institute of Engineering and Technology, Patiala for his expert
advice, technical suggestions and moral support during my thesis work.
Especially, I want to express my deepest appreciation and thanks to my supervisor
Mr. Sukhdev Chand for his support and untiring help in conducting my experiments. I
do not find enough words with which I can express my feeling of thanks to all my
teachers and friends at T.I.E.T., for their help, inspiration and moral support which went a
long way in completion of my thesis.
I am also thankful to the authors whose works I have consulted and quoted in this
work. I also extend my thanks to all faculty and staff members of Mechanical
Engineering Department, Thapar Institute of Engineering and Technology, for their direct
and indirect help and cooperation.
(Amit Gupta)
4
ABSTRACT
The problem of tool wear monitoring in machining operations, has been an active
area of research for quite a long time. The accurate prediction of tool wear is important to
have a better product quality and dimensional accuracy. In cutting tools the area close to
the tool tip is the most important region and conditions at the tool tip must be carefully
examined, if improvements in tool performance are to be achieved
The present work involves the study of tool wear caused by the change in
hardness of single point cutting tool for a turning operation to predict the tool life in
orthogonal cutting based on the heat transfer analysis using Finite Element Method
(FEM). The Experiments were performed with EN24 steel as workpiece and Carbide
uncoated tool bit as a tool material and the flank wear has been measured experimentally.
An empirical relation is used to determine temperature at tooltip and further Finite
Element Method is used to determine the distribution of temperature over the surface of
tool and its impact on hardness which is related by an empirical relations.
The study shows the effect of Modified temperature due to strain rate on carbide
tool to describe the thermal softening of tool material and becomes prone to wear. The
results reveal that by increasing process variables in machining the wear and temperature
increases causing thermal softening of tool causing it to wear.
The results obtained have been verified with the available results from literature
for the variation of wear with the temperature and thermal softening of carbide tool. The
results prescribed demonstrate the significance of cutting parameters (speed, feed and
depth of cut) in thermal analysis for study of the cutting tool wear.
5
INDEX
CONTENTS PAGE NO.
NOMENCLATURE (i)
LIST OF FIGURES (ii)
LIST OF TABLES (iii)
CHAPTER 1: Introduction 1  14
1.1 Tool Wear
1.1.1 Tool Wear Phenomena 24
1.1.2 Wear Mechanism 46
1.1.3 Prediction of Tool Wear 68
1.1.4 Tool Wear Models 810
1.2 Effects of the tool wear on technological performance
1.2.1 Consequences of tool wear 1011
1.2.2 Characteristics of tool wear 11
1.3 Thermal analysis
1.3.1 Heat Generation in Machining 1112
1.3.2 Analysis Techniques 1213
1.3.3 Heat Transfer in Machining 13
1.3.4 Heat Effects 14
1.3.5 Finite Element Method in Thermal Analysis 14
CHAPTER 2: LITERATURE REVIEW 1523
2.1 Models for determination of temperature field 1517
2.2 Application of FEM for tool wear research 1723
2.3 Summary of Literature 23
CHAPTER 3: INSTRUMENTATION AND EXPERIMENTATION 2428
3.1 Instrumentation
3.1.1 Force measurement 2426
3.2 Experimentation
3.2.1 Planning of experiment 26
3.2.2 Experimental procedure 2627
3.2.3 Experiment Methodology 2728
6
CHAPTER 4: ANALYSIS 2938
4.1 Governing equation for the heat transfer 29
4.2 Boundary condition 2930
4.3 FEM formulation 3037
4.4 Hardness of tool 37
4.5 Solution Scheme 37
4.6 Flow chart of Program 38
CHAPTER 5: RESULTS AND DISCUSSIONS 3950
5.1 Machining parameters used for experimentation 3941
5.2 Modeling of solution domain using FEM 4142
5.3 Validation of results 42
5.4 Variation of Hardness with FlankEdge Distance 4243
5.5 Variation of Temperature with Cutting Force 4344
5.6 Variation of Flank Wear with Cutting Force 44
5.7 Variation of Flank Wear with Modified Cutting Tool Temperature 4445
5.8 Regression Equation 45
5.9 Variation of Temperature with Cutting Velocity 4547
5.10 Variation of Flank Wear with Cutting Velocity (for Const. feed rate) 4748
5.11 Variation of Flank Wear with Cutting Velocity (for Const.depth of cuts)4849
5.12 Conclusions 49
5.13 Scope for Further Work 50
APPENDIX A 51
APPENDIX B 52
APPENDIX C 53
REFERENCES 5457
7
NOMENCLATURE
DIMENSIONAL PARAMETERS
Z Y X , , : Cartesian coordinate system
η ξ, : Local coordinates
Γ Ω, : Solution Domains
K : Conductivity coefficient
h : Convection coefficient
V : Cutting velocity
d : Depth of cut
f : Feed rate
φ : Shear Angle
α : Rake Angle
Q : Internal heat
.
γ : Strain Rate
.
o
γ : Reference Strain Rate
ν : Poisson’s Ratio
MATRICES AND VECTORS
  J : Jacobian matrix
  N : Shape function matrix
 
c
K : Conductivity matrix
 
h
K : Convection matrix
{ }
h
R : Convection load vector
{ }
q
R : Heat flux load vector
{ } T : Nodal pressure vector
(i)
8
LIST OF FIGURES
Fig 1.1: Types of Tool Wear 3
Fig 1.2: Behaviour of Flank wear 3
Fig 1.3: Wear mechanisms 6
Fig 1.4: Influencing elements of tool wear 7
Fig 1.5: Zones of heat generation & dissipation during the metal cutting process 12
Fig 2.1: Schematic of cutting tool with zero degree rake angle, where w is the
Tool widths, VB the flank wear and θ is the relief angle 21
Fig 3.1 Wheatstone bridge 25
Fig 3.2 Dynamometer 25
Fig 3.3 Dimensions of the workpiece 27
Fig 3.4 Schematic diagram of the lathe and equipment setup 28
Fig.4.1 Model of chip formation used in Oxley’s analysis for Orth. machining 29
Fig 5.1 Relationship between Cutting tool temperature and flank distance 42
Fig 5.2 Relation between hardness and flank distance 43
Fig 5.3 Variation of Temperature with resultant cutting force 43
Fig 5.4 Variation of Flank Wear with the resultant cutting force 44
Fig 5.5 Variation of flank Wear with respect to modified temperature 44
Fig 5.6 Relation between Cutting velocity and temperature at feed rate (f = 1) 45
Fig 5.7 Relation between Cutting velocity and temperature at feed rate (f = +1) 46
Fig 5.8 Variation of Temperature versus cutting velocity at depth of cut (d = 1) 46
Fig 5.9 Variation of Temperature versus cutting velocity at depth of cut (d = +1) 47
Fig 5.10 Variation of flank wear with cutting velocity at constant feed rate(f = 1) 47
Fig 5.11 Variation of flank wear with cutting velocity at constant feed rate(f= +1) 48
Fig 5.12 Variation of flank wear with cutting velocity at constant depth of cut(d = 1) 48
Fig 5.13 Variation of flank wear with cutting velocity at constant depth of cut (d = +1) 49
FigAC.1 Convection faces used in FEM analysis of Carbide cutting tool 53
(ii)
9
LIST OF TABLES
Table 1.1 Tool life and Tool wear rate models 9
Table 5.1 Cutting parameters 39
Table 5.2 Experimental Results of measured parameters against parameters V, f and d 40
(iii)
10
CHAPTER  1
INTRODUCTION
Tool wear monitoring/sensing should be one of the primary objectives in order to
produce the required end products in an automated industry so that a new tool may be
introduced at the instant at which the existing tool has worn out, thus preventing any
hazards occurring to the machine or deterioration of the surface finish. Cutting tools may
fail due to the plastic deformation, mechanical breakage, cutting edge blunting, and tool
brittle fracture or due to the rise in the interface temperatures.
Throughout the world today, there is a continuous struggle for cheaper production
with better quality. This can be achieved only through optimal utilization of both material
and human resources. Machining operations comprise a substantial portion of the world’s
manufacturing infrastructure. They create about 15% of the value of all mechanical
components manufactured worldwide. Because of its great economic and technical
importance, a large amount of research has been carried out in order to optimize cutting
process in terms of improving quality, increasing productivity and lowering cost.
Tool wear influences cutting power, machining quality, tool life and machining
cost. When tool wear reaches a certain value, increasing cutting force, vibration and
cutting temperature cause surface integrity deteriorated and dimension error greater than
tolerance. The life of the cutting tool comes to an end. Then the cutting tool must be
replaced or ground and the cutting process is interrupted. The cost and time for tool
replacement and adjusting machine tool increases cost and decreases the productivity.
Hence tool wear relates to the economic of machining and prediction of tool wear is of
great significance for the optimization of cutting process.
At present, the prediction of tool wear is performed by calculating tool life
according to experiment and empirical tool life equations such as Taylor’s equation or its
extension versions. Although Taylor’s equation gives the simple relationship between
tool life and a certain cutting parameters, e.g. cutting speed, and is very easy to use, it
gives only the information about tool life. For the researcher and tool manufacturer tool
wear progress and tool wear profile are also concerned. Tool life equation gives no
information about the wear mechanism. But capability of predicting the contributions of
various wear mechanism is very helpful for the design of cutting tool material and
11
geometry. In addition, such tool life equations are valid under very limited cutting
conditions. For example, when tool geometry is changed, new equation must be
established by making experiment.
Mostly researchers concentrate on the study of wear mechanism and investigate
the mathematical relationship between wear due to various wear mechanisms and some
cutting process variables such as relative sliding velocity of workpiece material along
tool face, cutting temperature of tool face and normal pressure on tool face. Some tool
wear equations related to one or several wear mechanisms are also developed, such as
Usui’s tool wear equation [15], and [19].
In the recent decades, with the emergency of more and more powerful computer
and the development of numerical technique, numerical methods such as finite element
method (FEM), finite difference method (FDM) and artificial Intelligence (AI) are widely
used in machining industry. Among them, FEM has become a powerful tool in the
simulation of cutting process because various variables in the cutting process such as
cutting force, cutting temperature, strain, strain rate, stress, etc can be predicted by
performing chip formation and heat transfer analysis in metal cutting, including those
very difficult to detect by experimental method. Therefore a new tool wear prediction
method may be developed by integrating FEM simulation of cutting process with tool
wear model.
1.1 TOOL WEAR
Cutting tools are subjected to an extremely severe rubbing process. They are in
metaltometal contact, between the chip and work piece, under conditions of very high
stress at high temperature. The situation is further aggravated due to the existence of
extreme stress and temperature gradients near the surface of the tool. During cutting,
cutting tools remove the material from the component to achieve the required shape,
dimension and finish. However, wears are occurring during the cutting action, and it will
result in the failure of the cutting tool. When the tool wear reach certain extent, the tool
or edge change has to be replaced to guarantee the ordinary cutting action.
1.1.1 TOOL WEAR PHENOMENA
Under high temperature, high pressure, high sliding velocity and mechanical or
thermal shock in cutting area, cutting tool has normally complex wear appearance, which
12
consists of some basic wear types such as crater wear, flank wear, thermal crack, brittle
crack, fatigue crack, insert breakage, plastic deformation and buildup edge. The
dominating basic wear types vary with the change of cutting conditions. Crater wear and
flank wear shown in figure1.1 are the most common wear types [28].
Figure1.1: Types of Tool Wear
• Crater wear: In continuous cutting, for example in turning operation, crater wear
normally forms on rake face. It conforms to the shape of the chip underside and reaches
the maximum depth at a distance away from the cutting edge where highest temperature
occurs. At high cutting speed, crater wear is often the factor that determines the life of the
cutting tool, because the tool edge is weakened by the severe cratering and eventually
fractures. Crater wear is improved by selecting suitable cutting parameters and using
coated tool or ultrahard material tool. Crater wear and flank wear shown in figure1.1 are
the most common wear types.
Figure 1.2: Behaviour of Flank wear
13
• Flank wear: Flank wear is caused by the friction between the newly machined work
piece surface and the tool flank face. It is responsible for a poor surface finish, a decrease
in the dimension accuracy of the tool and an increase in cutting force, temperature and
vibration. Hence the width of the flank wear land “VB” is usually taken as a measure of
the amount of wear and a threshold value of the width is defined as tool reshape criterion.
Figure1.2 shows a variation of flank wear rate with cutting time, showing the initial wear,
steady wear, and severe wear periods.
1.1.2 WEAR MECHANISM
In order to find out suitable way to slow down the wear process, many research
works are carried out to analyze the wear mechanism in metal cutting. It is found that tool
wear is not formed by a unique tool wear mechanism but a combination of several tool
wear mechanisms.
Tool wear mechanisms in metal cutting include abrasive wear, adhesive wear,
delamination wear, solution wear, diffusion wear, oxidation wear, electrochemical wear,
etc. Among them, abrasive wear, adhesive wear, diffusion wear and oxidation wear are
very important.
• Abrasive wear: Abrasive wear is mainly caused by the impurities within the
workpiece material, such as carbon, nitride and oxide compounds, as well as the builtup
fragments. This is a mechanical wear, and it is the main cause of the tool wear at low
cutting speed.
• Adhesive wear: The simple mechanism of friction and wear proposed by Bowden
and Tabor is based on the concept of the formation of welded junctions and subsequent
destruction of these. Due to the high pressure and temperature, welding occurs between
the fresh surface of the chip and rake face because of the chip flowing on the rake face
results in chemically clean surface.
Severe wear is characterized by considerable welding and tearing of the softer
rubbing surface at high wear rate, and the formation of relatively large wear particles.
Adhesion wear occurs mainly at low machining temperatures on tool rake face, such built
up edge (BUE).Under mild wear conditions, the surface finish of the sliding surfaces
improves.
14
• Diffusion wear: Wear is a process of atomic transfer at contacting asperities. A
number of workers have considered that the mechanism of tool wear must involve
chemical action and diffusion. They have demonstrated welding and preferred chemical
attack of (W) tungsten carbide in (WTi) tungstentitanium carbides. There are several
ways in which the wear may be dependent on the diffusion mechanism.
(i) Gross softening of the tool: Diffusion of carbon in a relatively deep surface layer of
the tool may cause softening and subsequent plastic flow of the tool. This flow may
produce major changes in the tool geometry, which result in high forces and a sudden
complete failure of the tool.
(ii) Diffusion of major tool constituents into the work (Chemical element loss): The
tool matrix or a major strengthening constituent may be dissolved into the work and chip
surfaces as they pass the tool. In cast alloy, carbide or ceramic tools, this may be the
prime wear phenomenon. With HSS tools, iron diffusion is possible, but it seems unlikely
to be the predominant wear process. Diamond tool – cutting iron and steel is the typical
example of diffusion wear.
(iii) Diffusion of a workmaterial component into the tool: A constituent of the work
material diffusing into the tool may alter the physical properties of a surface layer of the
tool. For example, the diffusion of lead into the tool may produce a thin brittle surface
layer, this thin layer can be removed by fracture or chipping.
• Oxidation wear: High temperatures and the presence of air mean oxidation for most
metals. A slight oxidation of tool face is helpful to reduce the tool wear. It reduces
adhesion, diffusion and current by isolating the tool and the workpiece. But at high
temperature soft oxide layers, for example Co
3
O
4
, WO3, TiO
2
, are formed rapidly, and
then taken away by the chip and the workpiece. This results in a rapid tool material loss,
which is oxidation wear.
• Chemical wear: Corrosive wear (due to chemical attack of a surface)
• Fatigue wear: Fatigue wear is often a thermomechanical combination. Temperature
fluctuations and the loading and unloading of cutting forces can lead to cutting edge
cracking and breaking. Intermittent cutting action leads to continual generation of heat
and cooling as well as shocks of cutting edge engagement.
15
Under different cutting conditions dominating wear mechanisms are different. For
a certain combination of cutting tool and workpiece, the dominating wear mechanisms
vary with cutting temperature, as shown in figure1.3. According to the temperature
distribution on the tool face, it is assumed that crater wear is mainly caused by abrasive
wear, diffusion wear and oxidation wear, but flank wear mainly dominated by abrasive
wear due to hard second phase in the workpiece material.
Figure 1.3: Wear mechanisms
1.1.3 PREDICTION OF TOOL WEAR
Prediction of tool wear is complex because of the complexity of machining
system [15]. Tool wear in cutting process is produced by the contact and relative sliding
between the cutting tool and the work piece and between the cutting tool and the chip
under the extreme conditions of cutting area; temperature at the cutting edge can exceed
530°C and pressure is greater than 13.79 N/mm
2
. Any element changing contact
conditions in cutting area affects tool wear. Figure 1.4 shows influencing elements of the
tool wear [15]. These elements come from the whole machining system comprising
workpiece, tool, interface and machine tool:
• Workpiece: It includes the workpiece material and its physical properties
(mechanical and thermal properties, microstructure, hardness, etc), which determine
cutting force and energy for the applied cutting conditions.
16
Figure 1.4: Influencing elements of tool wear
• Tool: Tool material, tool coatings and tool geometric design (edge preparation, rake
angle, etc) need to be appropriately chosen for different operations (roughing, semi
roughing, or finishing). The optimal performance of a cutting tool requires a right
combination of the above tool parameters and cutting conditions (cutting speed, feed rate,
depth of cut)
• Interface: It involves the interface conditions. In 80% of the industrial cutting
applications, coolants are used to decrease cutting temperatures and likely reduce tool
wear. Increasingly new technologies, such as the minimum liquid lubrication, have been
developed to reduce the cost of coolant that makes up to 16% of the total machining
costs.
• Dynamic: The dynamic characteristic of the machine tool, affected by the machine
tool structure and all the components taking part in the cutting process, plays an
important role for a successful cutting. Instable cutting processes with large vibrations
(chatters) result in a fluctuating overload on the cutting tool and often lead to the
premature failure of the cutting edge by tool chipping and excessive tool wear.
The problem of tool wear monitoring in machining operation has been active area
of research. This is because tool change strategies, product quality, tooling costs, and
17
productivity are all influenced by tool wear. Reduction in production cost and increase in
productivity can be realized by making the most use of a tool’s life and therefore
increasing the time between tool changes.
1.1.4 TOOL WEAR MODELS
Many mathematical models are developed to describe tool wear in quantity. They
can be categorized into two types: Tool life models and Tool wear rate models, and have
been elaborated below.
Tool life models: This type of wear models gives the relationship between tool life and
cutting parameters or variables. For example, Taylor’s tool life equation reveals the
exponential relationship between tool life and cutting speed, and Hastings tool life
equation describes the great effect of cutting temperature on tool life [19], as shown in
table 1.1. The constants n, C
1
, A and B are defined by doing a lot of experiments with
cutting speed changing and fitting the experimental data with the equation. It is very
convenient to predict tool life by using this equation. In various sizes of cutting database,
Taylor’s tool life equation and its extension versions under different cutting conditions
appear most frequently.
Tool life equations are suitable to very limited range of cutting conditions. As the
new machining technologies, e.g. highspeedcutting or dry cutting, are getting spread in
manufacturing industry, the existing tool life equations need to be updated with new
constants and a lot of experimental work has to be done. In addition, except that tool life
can be predicted by these equations, it is difficult to get further information about the tool
wear progress, tool wear profile or tool wear mechanisms that are sometimes important
for tool designers.
Tool wearrate models: These models are derived from one or several wear
mechanisms. They provide the information about wear growth rate due to some wear
mechanisms. In these modes, the wear growth rate, i.e. the rate of volume loss at the tool
face (rake or flank) per unit contact area per unit time (mm/min), are related to several
cutting process variables that have to be decided by experiment or using some methods.
18
Table 1.1: Tool life and Tool wear rate models
Empirical Tool Life Models Tool Wear Rate Models
Taylor’s basic equation:
VL
n
= C
1
( n,C
1
= Constants )
Taylor’s extended equation:
r q p
d f V
C
L
2
= ( p,q,r,C
2
= constants)
Takeyama & Murata’s wear model
(considering abrasive wear and
diffusive wear):

¹

\
 −
+ =
RT
E
D f v G
dt
dW
exp ) , (
(G,D =constants)
Taylor’s extended equation:
r q p m
BHN d f L
C
V
) 200 / (
3
=
( m,p,q,r,C
3
= constants)
Temperaturebased equation(known as
Hasting’s tool life equation):
A TL
B
=
( A,B =constants)
Usui’s wear model
(considering adhesive wear):

¹

\
 −
=
T
B
V A
dt
dW
s n
exp σ
(A,B = Constants)
V = Cutting speed ,L = Tool life ,
n
σ = Normal Stress, f = Feed rate, d = Depth of cut
T = Cutting temperature ,BHN = Workpiece hardness, E = process activation energy
Vs = sliding velocity ,R = universal gas constant ,
dW/dt = wear rate (volume loss per unit contact area per unit time)
Takeyama & Murata’s model is developed by considering the combination action
of abrasive wear and diffusive wear. Therefore the equation sums two parts up. One part
shows that abrasive wear is influenced by the cutting speed and feed. Another part
including universal gas constant and tool temperature describes diffusive wear.
Usui’s equation includes three variables: Sliding velocity between the chip and
the cutting tool, tool temperature and normal pressure on tool face. These variables can
be predicted by FEM simulation of cutting process or combining analytical method and
FDM. Therefore Usui’s equation is very practical for the implementation of tool wear
estimation by using FEM or by using the combination of FDM and analytical method.
19
The constants in tool wear rate models are depending on the combination of workpiece
and cutting tool material.
1.2 EFFECTS OF TOOL WEAR ON TECHNOLOGICAL
PERFORMANCE
1.2.1 CONSEQUENCES OF TOOL WEAR
• Decrease the dimension accuracy;
• Increase the surface roughness;
• Increase the cutting force;
• Increase the temperature;
• Likely cause vibration;
• Lower the production efficiency, component quality;
• Increase the cost.
Influence on cutting forces: Flank wear (or wearland formation) and chipping of the
cutting edge affect the performance of the cutting tool in various ways. The cutting forces
are normally increased by wear of the tool. Crater wear may, however, under certain
circumstances, reduce forces by effectively increasing the rake angle of the tool.
Clearanceface (flank or wearland) wear and chipping almost invariably increase the
cutting forces due to increased rubbing forces.
Surface finish (roughness): The surface finish produced in a machining operation
usually deteriorates as the tool wears. This is particularly true of a tool worn by chipping
and generally the case for a tool with flankland wear – although there are circumstances
in which a wear land may burnish (polish) the workpiece and produces a good finish.
Dimension accuracy: Flank wear influences the plan geometry of a tool this may affect
the dimensions of the component produced in a machine with set cutting tool position or
it may influence the shape of the components produced in an operation utilizing a form
tool.
Vibration or chatter: The vibration is another aspect of the cutting process which may
be influenced by flank wear. A wear land increases the tendency of a tool to dynamic
20
instability. A cutting operation which is quite free of vibration when the tool is sharp may
be subjected to an unacceptable chatter mode when the tool wears.
1.2.2 CHARACTERISTICS OF TOOL WEAR
• Huge contact stress at the rake and flank surface
• High temperature (8001000 °C for carbide and steel combination)
Hence, generalized wear theory cannot be directly used for accurate study of the
tool wear.
1.3 THERMAL ANALYSIS:
In machining operations, mechanical work is converted to heat through the plastic
deformation involved in chip formation and through friction between the tool and
workpiece. Some of this heat conducts into cutting tool, resulting in high tool
temperatures near cutting edge. Elevated tool temperatures have negative impact on a
tool life. The temperature of the tool plays an important role in the thermal distortion and
the, machined part’s dimensional accuracy, as well as in the tool life in machining. Tools
become softer and wear more rapidly by abrasion as temperatures are increased, and in
many cases constituents of the tool life may diffuse into the chip or react chemically with
the workpiece or cutting fluid.
1.3.1 HEAT GENERATION IN MACHINING
Heat generation while machining has significant influence on machining. It can
increases tool wear and thereby reducing tool life [17]. It gives rise to thermal softening
of cutting tool. It is commonly accepted that both the wear and failure mechanisms which
develop in cutting tools are predominantly influenced by temperature and it also results in
modification to the properties of workpiece and tool material such as hardness. In order
to predict the wear and failure characteristics of a tool, it is necessary to quantify the
temperatures which develop during the cutting operation.
In machining operations, mechanical work is converted to heat through the plastic
deformation involved in chip formation and through friction between the tool and
workpiece. Figure 1.5 shows three regions of heat generation in turning; which are, the
shear zone, the chiptool interface and the toolworkpiece interface zone [17]:
21
• The shear zone: The shear zone, where the main plastic deformation takes place due
to shear energy. This heat raises the temperature of the chip. Part of this heat is carried
away by the chip when it moves upward along the tool. Considering a continuous type
chip, as the cutting speed increases for a given rate of feed, the chip thickness decreases
and less shear energy is required for chip deformation so the chip is heated less from this
deformation. About 8085% of the heat generated in shear zone.
• The chiptool interface zone: The chiptool interface zone, where secondary plastic
deformation due to friction between the heated chip and tool takes place. This causes a
further rise in the temperature of the chip. This chiptool interface contributes 1520% of
heat generated.
Figure 1.5: Zones of heat generation & dissipation during the metal cutting process.
• The toolworkpiece interface zone: The worktool interface zone 3, at flanks where
frictional rubbing occurs. This area contributes 13% of heat generated.
As the portion of heat that flows into the tool cause very high temperature in
vicinity of tool tip which in turn decrease the hardness of the tool material and in extreme
case may even cause melting. The wear rate of tool therefore increases, resulting in a
decrease in useful life of the tool. It is increasingly important to understand how
machining temperature are affected by the process variable involved which are cutting
speed, feed rate, and tool geometry.
1.3.2 ANALYSIS TECHNIQUES
Several methods have been used for measuring the temperatures generated during
metal cutting operations [12]. The main techniques used to evaluate the temperature
during machining are as following:
22
Experiment Retrospection: Many experimental methods have been devised to measure
the tool, chip or workpiece temperature and their distribution, these are:
• ToolChip Thermocouple Technique
• Embedded Thermocouple Technique
• Infrared Radiation Technique
• Metal Microstructure and Microhardness Variation Measurement
• Thermosensitive Painting Technique
• Temper Color Technique
Numerical Simulation: The numerical methods were successfully applied in calculating
the temperature distribution and thermal deformation in tool, chip and workpiece.
Especially, the finite element and boundary element methods can deal with very
complicated geometry in machining; they have great potential to solve the problems in
practice. These numerical methods used in measurement of temperatures are the
following:
• Finite Difference Method
• Finite Element Method
• Boundary Element Method
SemiAnalysis: In the semi analysis technique, some information such as chip surface
temperature or temperature distribution in workpiece is first obtained experimentally.
Then the temperature distribution and/or thermal deformation in chip and sometimes in
the tool and workpiece as well are calculated analytically. The inverse heat transfer
problem in machining is an example of these methods.
1.3.3 HEAT TRANSFER IN MACHINING
Heat is transferred across boundaries by conduction, convection and radiation
because of the temperature gradient, and air present at ambient temperature [8].
• Heat transfer inside the chip and workpiece, the tool and toolholder is by conduction.
• Heat transfer between coolant/air and the chip/tool/workpiece is by convection.
• Radiation is rarely investigated in traditional machining operations.
23
1.3.4 HEAT EFFECTS
In metal cutting, severe deformations take place in the vicinity of the cutting edge
of the tool because of the high temperatures resulting from machining operation. These
elevated temperatures have a negative impact on tool life, and quality of surface.
Following are some of the effects of heat on various cutting parameters:
• Heat Influences on Cutting Forces: The heat influence on the cutting forces is mainly
because of the following reasonsthe friction coefficient is tightly dependent upon
temperature, and the properties of cut material also depend on temperature.
• Heat Effects on Tool Life
• Heat Influences on Surface Toughness
• Heat Influences on Thermal Deformation in Lathe.
• Heat Effects on Mass Transfer in Coolant Circulation System.
1.3.5 Finite Element Method in Thermal Analysis
Finite element analysis is a most useful and accurate approach for the
determination of field variables that is made possible by advancements in computational
and processing power of computers and thus it is almost used for all the computer aided
design methodologies in recent years. Applications range from deformation and stress
analysis to field analysis of heat flux, fluid flow, magnetic flux, seepage and other flow
problem. In this method of analysis, a complex region defining a continuum is discredited
into simple geometric shapes called finite elements. The Present work is also based on
the application of finite element for thermal analysis of single point cutting tool for
turning operation. Once the model developed for determination of temperature field for
single point cutting tool, it can also be implemented for other multipoint processes like
drilling, milling or grinding also.
24
CHAPTER  2
LITERATURE REVIEW
The problem of tool wear monitoring in machining operations has been an active
area of research for quite some time. The machining processes are inherently dynamic in
nature due to various factors. Some of them can be mathematically modeled, but others
are too uncertain. Thus simplifications are made while modeling the extremely complex
machining processes. Research in the field of machining has been primarily done on
single point turning process, as it is the basic metal removal processes. Once a model has
been developed for turning operation, it can be implemented for other multipoint
processes like drilling, milling or grinding.
In this work tool wear along with temperature had been selected as the criterion
for the process control in turning operation. In recent years, numerical calculating
methods have been widely developed in most areas of engineering and have been used to
determine the thermal behaviour of cutting tools. In general, the application of finite
element and finite difference techniques has been successful, yet still relies heavily on the
accuracy of experimentally determined boundary conditions.
This chapter deals with the review of the work done on the topic. Firstly the
review is on the general analysis of tool, concentrating mainly on prediction of
temperature and tool wear. Then the concentration shifts on to second part, which is the
review on use of finite element in the thermal analysis of the cutting tool.
2.1 MODELS FOR DETERMINATION OF TEMPERATURE FIELD
Temperature measurement and prediction have been a major focus of machining
research for several decades. Throughout the 20
th
century, much effort has been
undertaken into measuring the temperature generated during cutting operations.
Interfacial temperatures in machining play a major role in tool wear and can also result in
modification to the mechanical properties of the workpiece and cutting tool.
Leshock et al [4] presented the results the tool chip interface temperature
measurement by the tool work thermocouple technique. Tool chip interface temperature
is analyzed under a wide range of cutting condition during turning of 4140 steel alloys
and Inconel 718 nickel based alloys with tungsten carbide tools. The obtained
experimental results are compared with the predictions based on the Loewen and Shaw’s
25
model. In addition an empirical model for the tool face temperature terms of cutting
parameters is established. Finally, the tool chip interface temperature is analyzed with
both flank and crater wear during machining of 4140 steel alloys.
Sullivan et al [12] presented different methods used for the measurement of
temperature of a single cutting tool. Initial experiments conducted involved the
simultaneous measurement of forces & temperature. Use of the toolchip interface as a
thermocouple was one of the first methods of estimating interfacial temperatures in
machining process. These experiments focused on the use of embedded thermocouples
and using the infrared camera to monitor the process.
Komanduri et al [13] addresses two fundamental thermal issues of tribology in
orthogonal machining with a sharp tool, namely, the nature of the apparent heat partition
in the shear plane and the variable heat partition at the chiptool interface. The
distribution of temperature in the chip, the tool, and the work material was determined
analytically considering the combined effect of these two heat sources in orthogonal
machining. The new analytical model was verified for a wide range of Peclet numbers,
using the available experimental data from the literature.
Huda et al [14] developed a technique for measuring temperature at the interface
between a cutting tool and a chip. A twocolor pyrometer with fused fiber coupler was
applied to the temperature measurement of the toolchip interface in dry and wet turning.
By using this pyrometer, it is possible to measure the temperature of a very small object
without emissivity affecting the results. The temperature distributions on the cutting tool
and the work material were analyzed using the finite element method. Good agreement
was obtained between the analytical results and experimental ones.
Miller et al [21] developed Experimental techniques using modern, digital
infrared imaging and successfully applied them during this study to gather cutting tool
temperature distributions from orthogonal machining operations. This new process has
seemingly overcome many problems associated with past experimental techniques.
Ranc et al [23] developed a highspeed broad band visible pyrometer using an
intensified CCD camera (spectral range: 0.4 mm–0.9 mm) for the measurement of the
machining temperature. The maximum temperature in the chip can reach 730°C and
minimal temperature which can be detected is around 550°C. The advantage of the
26
visible pyrometry technique is to limit the temperature error due to the uncertainties on
the emissivity value and to have a good spatial resolution (3.6 mm) and a large
observation area.
2.2 APPLICATION OF FEM FOR TOOL WEAR RESEARCH
A more promising approach for developing an orthogonal metal cutting model is
provided by an advanced numerical discretization scheme, such as the finite element
method. This part basically discusses about the application of FEM in predicting the tool
temperature and thus estimating the tool wear.
Shih et al [1] developed the, methodology using FEM for the simulation of plane–
strain orthogonal cutting processes with continuous chip formation. The orthogonal metal
cutting experiment was setup on a shaper, and the distributions of the residual stresses of
the annealed carbon steel are measured using the Xray diffraction method. Along with
this, they also developed experimental procedures for orthogonal metal cutting and
measurement of distributions of residual stresses using the Xray diffraction method.
They formulated a 4 nodes 8 degree of freedom, quadrilateral plane–strain finite element.
The finite element formulation was divided in two phases. Only thermal finite element
formulation is discussed here.
• Thermal finite element formulation: The temperature increment during the metal
cutting process is simulated using a linear thermal finite element formulation by
assuming that the thermal conductivity, density and heat capacity of the workpiece
material remain unchanged during the displacement increment. The thermal finite
element formulation for temperature analysis can be written in a matrix form as
( ){ }
)
`
¹
¹
´
¦
+
)
`
¹
¹
´
¦
= + +
)
`
¹
¹
´
¦
. . .
] [ ] [ ] [ Ft Fp T K K T C
c k
(2.1)
Where, [C] =
∫
v
T
cdV N N ρ } }{ {
[K
k
]= kdV B B
T
v
] [ ] [
∫
[K
c
]=
∫
c
S
c
T
hdS N N } { } {
27
{
p
F
.
}=
{ } dV q N
v
∫
&
Here, {T} = Temperature vector at nodal points
{N} = Shape function vector
c = Heat capacity of workpiece
h = Convection coefficient
S
c
= Convection boundary of the workpiece
{
p
F
.
} = Vector of heat generation due to plastic work
.
q = Rate of plastic work
{
t
F
.
} = Heat generation rate on the boundary node of the workpiece due to
frictional work
k c, , ρ , and h are all assumed as direction independent.
Based on the equation (2.1), the temperature distribution of the workpiece is
obtained and the material properties are thus generated.
Shih [2] developed plane – strain Finite Element Method and applied to analyze
the orthogonal metal cutting process. Detailed workmaterial modeling, which included
the coupling of large strain, high strain rate and temperature effects, was used to simulate
the material deformation during cutting process. The finite element predictions of the
residual stresses were compared with measurements obtained from Xray diffraction.
They concluded that finer element mesh configuration should be used to achieve more
accurate modeling of the cutting process and also to improve the FE predictions.
Gillibrand et al [3] developed a technique to predict the temperatures generated
along the tool/chip interface using standard analytical methods. The temperature
distribution along the tool/chip interface is applied as a heat source input to a finite
element model of the tool. They developed a package for estimating the thermal behavior
of both single and multipoint cutting tools using base data which are generally available,
or may be acquired through standard cutting tests. They concluded that with the
continued development of surface engineered cutting tools, and the product testing
involved, this easytoapply, rapid, lowcost package would be useful for giving an
indication of the expected thermal behavior of surface engineered cutting tools.
28
Mills et al [5] developed a technique to monitor the deformation and crack
propagation around inclusions using a micro cutting device in a scanning electron
microscope while machining is being carried out. The temperature distribution field
within a cutting tool under conditions of adherent layer formation was determined using
the FEM. It was found that the temperature gradient in the cutting tool from the tool face
at a position 0.25 to 0.5 mm from the major cutting edge is much smaller in the presence
of an adherent layer than without an adherent layer.
Tieu et al [6] presented a research work carried out on the cutting tool temperature
field with adhering layer formation when machining CaS treecutting stainless steel. By
means of combining thermocouple measuring method and finite element (FE) analysis,
the cutting temperature distributions and their relation with the formation of adhering
layer were investigated. Based on the experimental work using a miniature thermocouple
and the analytical results from FE modeling, they concluded that the adhering layer
thickness was uneven and the average temperature of cutting zone for adhering layer
formation was within a range of 9501050°C.
Chu et al [7] developed technique for measuring temperature close to primary
cutting edge in turning operation. The cutting temperatures of a 0.16 % carbon bright
drawn mild steel, have been measured for a range of cutting speed and feedrates at a
constant depth of cut. Tool nose radius was also varied. The correlations for workpiece
temperature of cutting speed & feed have been developed. It showed that cutting speed &
feed rates have significant impact on temperature but nose radius has little effect.
Ostafiev et al [8] analyzed heat flux transfer in the cutting tool in steady state
orthogonal cutting. The method involved as interactive procedure to determine
temperature distributions in the tool from varying heat flux transfer conditions. The
temperature distributions determined from this procedure were compared with those
obtained experimentally. A coincidence of the experimental and theoretical temperature
distributions implied that the chosen heat flux model was appropriate.
Yen et al [15] developed a methodology to estimate the tool wear of carbide tool
in orthogonal cutting using FEM. In metal cutting, tool wear is strongly influenced by the
cutting temperature, contact stresses, and relative sliding velocity at the interface. These
process variables depend on tool and workpiece materials, cutting condition, tool
29
geometry, use of coolants etc, for the given application. Based on temperatures and
stresses on the tool face, tool wear may be estimated with acceptable accuracy by using
an empirical wear model and using FEM simulation. The methodology proposed by them
has three different phases, the first phase includes, a development of tool wear model for
the specified toolworkpiece pair, the second phase includes, modifications in the
commercial FEM code and last phase includes experimental validation of the developed
methodology. The wear prediction procedure starts with a coupled thermoviscoplastic
Lagrangian cutting simulation with isotropic strainhardening using DEFORM
®
2D. In
order to obtain the cut chip geometry near the steady state, a special simulation module,
“KontiCut”, developed by WZL at University of Aachen (RWTH), Germany, was
utilized.
Zhao et al [18] developed a methodology to investigate the effects of the internal
cooling on the flank wear of the cutting tools in orthogonal cutting. A flank wear model
for a cutting tool in orthogonal cutting is presented which is based on previous wear
models and includes the normal stress and the effect of temperature on the flank wear.
According to the prediction of this model, the wear performance of carbide cutting tools
and HSS cutting tools are different due to their different thermal softening behavior, and
they have formulated the following methodologies:
1. Flank wear model for orthogonal metal cutting
In all the previous wear models studied by them, hardness H and normal stress
t
σ are two main parameters closely related to the wear and the wear rate is usually
proportional to
t
σ and inversely proportional to H. Mathematically wear can be expressed
as follows: dW = K
H
dL
t
σ
The wear volume can be converted to the wear land measurement VB with the
assumption of a zero degree rake angle of the cutting tool
W = θ tan
2
1
2
B
wV
Where, W is the volume worn away on the relief face, V
B
is the measurement of
wear land on the tool, w the width of cut and θ is the relief angle of the tool[18], as shown
30
in figure 2.1. The apparent area of the tool–work contact interface can be written as
follows: A = w V
B
The normal stress at the flank face can be calculated as given by the following
relation:
B
t t
t
wV
F
A
F
= = σ
Where F
t is
the thrust force in cutting .V
B
is a variable that increases with the
development of flank wear. Thus the equation to predict flank wear can be written as:
V
B
= K
3
1
3
1
2
tan
2

¹

\


¹

\

H
t F
w
V
t c
θ
Where, K is a coefficient which can be determined by experiments, L is the
cutting length, H is the hardness of the cutting tool, V
C is
the cutting speed, and t is the
cutting time.
Figure 2.1: Schematic of cutting tool with zero degree rake angle, where w is the tool width, V
B
the
flank wear and θ is the relief angle
2. Effects of temperature on flank wear in orthogonal cutting
To consider the effects of the temperature on the flank wear, it is necessary to
know the thermal softening of the cutting tool material versus the temperature. The
exponential function used to predict thermal softening is as follows:
H (T) = Ho exp (−αT)
Where H (T) is the hardness of a material at a given temperature, T is in
◦
C, H
o
and α are constants obtained by Curvefitting .Since the relationship between the thermal
31
softening and temperature can be obtained by curvefitting experimental data, different
equations can be used. The following is the equation used them:
H (T) =
4 3
2
2
3
1
C T C T C T C + + +
Where H is the hardness of the cutting tool material, T is the temperature in
◦
C
and C
1
, C
2
, C
3
and C
4
are constants that can be determined by curvefitting. The values of
C
1
, C
2,
C
3
and C
4
for different tool materials are:
For Carbide Tool Material
C
1
= 0.000006, C
2
= −0.0054, C3 = 0.5853, and C
4
= 1517.
For HSS Tool Material
C
1
= −0.000002, C
2
= 0.0002, C
3
= −0.2122, and C
4
= 853.81.
The flank wear in arbitrary units versus the temperature was calculated by them
for both carbide and HSS material.
YC Yen et al [19] developed a methodology to estimate the tool wear and tool life
of a carbide tool in orthogonal cutting using FEM simulation. The proposed procedure for
predicting the tool wear at any time instance t
k
was divided in four phases.
• “Konti Cut” Simulation
• Pure Heat Transfer Analysis
• Calculating Tool Wear Rate
• Updating the Tool Geometry
The simulations using a cutting tool with constantly updated rake face and flank
face geometries have shown that it is possible to predict the evolution of tool wear at any
given cutting time from FEM simulations by using the proposed methodology by them.
Amir et al [20] developed methodology to extend the applicability of Oxley’s
analysis of machining to a broader class of materials beyond the carbon steels used by
Oxley and coworkers. The performance of the model was studied by comparing its
predictions with experimental data for different materials and it was found that model
accurately produces the dependence of the cutting forces and chip thickness as a function
of undeformed chip thickness and cutting speed and accurately estimates the temperature
in the primary and secondary shear zones.
Arsecularatne et al [22] investigated the application of the Oxley modeling
approach to high speed machining (HSM) process for gaining a fundamental
32
understanding and performance prediction of this process which is gaining increased
popularity due to its many economic and technological advantages such as faster metal
removal rates, efficient use of machine tools and, improved surface finish and lower
cutting forces. In the present work, this theory has been applied for two plain carbon
steels and low alloy steel under HSM conditions. The predicted cutting forces, chip
thicknesses, and secondary deformation zone thicknesses are then compared with the
experimental results obtained under identical conditions. Good agreement has been
shown between measured and predicted results.
Moufki et al [26] developed an analytical approach for thermomechanical
modeling of oblique cutting process. The material characteristics such as strain rate
sensitivity, strain hardening and thermal softening were considered. A critical study was
also presented by them in order to show the influences of the input parameters of the
model including the normal shear angle, the thickness of the primary shear zone and the
pressure distribution at the tool–chip interface. The model permits to predict the cutting
forces, the chip flow direction, the contact length between the chip and the tool and the
temperature distribution at the tool–chip interface which has an important effect on tool
wear.
Molinari et al [27] developed an analytical approach to model the
thermomechanical process of chip formation in a turning operation. The model presented
can be used to predict the cutting forces, the global chip flow direction, the surface
contact between chip and tool and the temperature distribution at the rake face which
affects strongly the tool wear. The tendencies predicted by the model were also compared
qualitatively with the experimental trends founded in the literature.
2.3 SUMMARY OF LITERATURE
From above literature review, it can be concluded that FEM has been effectively
implemented to determine the temperature distribution on the tool surface, in order to
predict the tool wear. Since machining parameters affect the wear and heat generation in
tool, so further study has been carried out to develop the relation between machining
parameters and mechanical properties which are governed by modified machining
temperatures due to strain rate.
33
CHPATER  3
INSTRUMENTATION AND EXPERIMENTATION
The objective of the present work is to develop methodology to relate tool wear
with mechanical properties of a material such as Hardness. Here hardness is related with
the modified temperature, including the effect of strain rate, of cutting tool. Finite
Element Analysis is used to depict the temperature at various points of cutting tool by
changing various machining parameters such as cutting speed (V), depth of cut (d), feed
rate (f).
3.1 INSTRUMENTATION
The various instruments used for experimentation are discussed here in this
section:
3.1.1 FORCE MEASUREMENT
A force measurement actually involves the measurement of a deflection, caused
by that force, with a suitable calibration between the force and the deflection it produces.
For measuring small deflections, various devices have been used. Some of them are listed
below:
1. The dial indicator.
2. Pneumatic devices.
3. Optical devices.
4. Piezoelectric crystals.
5. Strain Gauges.
Out of these, most widely used dynamometer is of strain gauge type. In this
category, bounded wire strain gauges have commonly been used. Usually these bonded
wire gauges have been specified by the resistance and the gauge factor (F). The gauge
factor is a measure of sensitivity of gauge and is defined as:
R
R
l l
R R
F
∈
∆
=
∆
∆
=
Where, ∈ is the normal strain and can be calculated as:
l
l ∆
∈=
34
In our case, bonded wire strain gauge of resistance 120+ and gauge factor 2, have
been used. In order to measure the strains of the order of 1+, the changes of the resistance
of the same order of magnitude need to be measured. This can be made by means of
Wheatstone bridge as shown in figure 3.1[24]. No current will flow through the
galvanometer (G) if the four resistances satisfy the equation
3
2
4
1
R
R
R
R
=
For the sake of simplicity, the lathe operation is frequently taken as a orthogonal
cutting process. In this case, the resultant force will act in a known plane and only two
force components are required to analyze the cutting process. A schematic diagram of the
dynamometer used in the present work is shown in the figure 3.2[24]. In the present case,
the axial cutting force, Fc, and the tangential cutting force, Ff, have been used.
Figure 3.1: Wheatstone bridge
Figure 3.2: Dynamometer
35
A two component cutting force dynamometer of cantilever type is used in the
present work. The dynamometer structure is made of aluminum. The action of the forces
is to bend the structure. The axial cutting force, Fc, bends the structure about the one axis
and the tangential feed force, Ff, bends the structure about another axis. Strain gauges
have been used to measure these distortions (moments), and the recordings are calibrated
to give a measure of the forces applied.
3.2 EXPERIMENTATION
Experiments were carried out on a turning lathe. A carbide tip turning tool was
clamped in a two component strain gauge dynamometer using a tool holder designed in a
machine lab during the thesis work. For the experimentation, EN 24 steel workpiece of
600mm length was held in a three – jaw chuck and supported by a center in the tail stock.
Tool height and tool overhang was set to the required level with the help of gauges. A
rough turning pass was made initially to eliminate the runout of the workpiece. The
output flank wear was measured with the help of a tool room microscope. The straight
edge with Rake angle 0 = α has been used to have an orthogonal cutting.
3.2.1 PLANNING OF EXPERIMENT
A scientific approach to planning of experiments must be incorporated in order to
perform an experiment most effectively. Statistical design of experiments is the process
of planning the experiments so that the appropriate data could be collected which may be
analyzed by statistical method resulting in valid and objective conclusions.
Planning of experiments was employed in order to fulfill the following requirements:
• To get the data uniformity distributed over the whole range of controllable factors to
be investigated.
• To reduce the total number of experiments.
• To establish a relationship between different input variables and the output accurately
in the selected range of investigation
3.2.2 EXPERIMENTAL PROCEDURE
The experiments were made on the HMT lathe using a bar turning process under
dry conditions. For the range of range of cutting conditions (cutting speed, feed, and
depth of cut) it was required to measure the two force components F
t
and F
f
, thickness of
chip and flank wear. A total of eight experiments were carried out, all with the same basic
36
56 mm
configuration and carbide inserts were replaced after performing a single test so as to see
the effect of temperature on the tool individually at different cutting conditions. The
selected ranges of each parameter used are given below:
• Work material: The EN 24 Steel (0.35 0.45 %C, 0.45 0.6 %Mn, 1.3  1.8 %Ni)
was chosen for the present investigation with a diameter of 60 mm and 600 mm length.
600mm
Figure 3.3: Dimensions of the workpiece
The figure 3.3 shows the dimensions of the workpiece (EN24) before the turning
process.
• Tool material: The tool material used should be capable of high speed machining
with dry cutting conditions. In present investigation carbide inserts were used for
performing the experiments.
• Tool geometries:
a) Tool length: 16.02mm
b) Tool width: 8.02 mm
c) Nose radius: 0.4 mm
• Test conditions: carbide inserts were used to machine EN24 steel with following
cutting parameters
a) Rotational speed:70.08 – 179.82 (m/min)
b) Feed: 0.0787 – 0.175 (m/sec)
c) Depth of cut: 0.508,0.762,1.27 (mm)
3.2.3 EXPERIMENT METHODOLOGY
A HMT make lathe was used for turning experiment whose specifications have
been given in appendix A. Figure3.4 shows the schematic diagram of the machine and
equipment setup.
37
Cutting tool
Figure 3.4: Schematic diagram of the lathe and equipment setup
Then the actual experiments have been carried out with the different input cutting
conditions for different experiments for constant volume of material removal in each
case. The experiments carried out can be classified:
1. Carry out experiment on lathe machine using EN 24 as work piece and commercial
available Carbide Tool of triangular shape.
2. Machining is done with different sets of Cutting speed, depth of cut, & feed rates.
3. Measuring the cutting forces with dynamometer.
4. Measuring the deformed chip thickness using vernier calliper.
5. Measuring the flank wear of the carbide insert with microscope.
6. Correlating these wear trend with thermal softening of tool due to rise in temperature
in insert.
The output flank wear is measured with the help of a metallurgical microscope
having graduation marked on the eyepiece. These input cutting conditions are fed to
program and value of temperature and Hardness at every nodes of the tool is thus
calculated.
Workpiece
Dynamometer Display
38
CHAPTER  4
ANALYSIS
The present chapter deals with the formulation of threedimensional governing
equation for heat conduction used to obtain the temperature distribution on the face of the
tool bit, to be used for obtaining the hardness at the various positions on the tool. The
eight noded brick elements have been used for the FEM modeling.
4.1 GOVERNING EQUATION FOR THE HEAT TRANSFER
Governing equation for the heat transfer problem can be written as:

¹

\

∂
∂
∂
∂
x
T
K
x
+


¹

\

∂
∂
∂
∂
y
T
K
y
+ 
¹

\

∂
∂
∂
∂
z
T
K
z
+Q = 0 (4.1)
Following assumptions have been considered for the simplicity if the computation
required:
1. Conduction occurs in the steady state,
2. Material is isotropic and homogeneous as (K
x
= K
y
= K
z
= K)
3. Internal heat generation is zero.
This equation is solved with appropriate boundary conditions, and heat transfer is
considered in threedimensional solid Ω bounded by a surface Γ.
4.2 BOUNDARY CONDITION
Following boundary conditions have been used for the solution of the present problem:
1. Temperature is specified at nodes which are in touch with shear zone[1], [4], [20],and
[22], and have been calculated by relation given below:
T
mod
(
o
K) = T
avg



¹

\

−
.
.
log 1
o
γ
γ
ν
Here,
y
V
∆ −
= .
) ( cos
cos
.
α φ
α
γ


¹

\

−
=
−
α
α
φ
sin 1
cos
tan
1
r
r
Figure 4.1: Model of chip formation used
in Oxley’s analysis for Orth. machining
39
y ∆ = spacing between successive planes (25 *10
4
mm)
4 . 0 2 . 0 5 . 0
int .
1700 ) ( f d V C T
erface avg
=
ο
2. Convection is taking place on surface from the tool bit to air, taking
Where, C T
ο
27 =
∞
) (
∞
− = T T h q
n
h
air
=14 W/m
2 o
C
n
q = Heat flux normal to the boundary
∞
T = Ambient temperature
4.3 FEM FORMULATION
Using Galerkin’s orthogonality, equation (4.1) becomes;
∫ ∫
Ω Ω
= Ω + Ω


¹

\


¹

\

∂
∂
∂
∂
+


¹

\

∂
∂
∂
∂
+ 
¹

\

∂
∂
∂
∂
0 d QN d N
z
T
K
z y
T
K
y x
T
K
x
i i
(4.2)
Where dz dy dx d . . = Ω
Now, since internal heat generation has been assumed to be zero;
Thus,
0 = Ω
∫
Ω
d QN
i
The various components of equation (4.2) can be obtained from the relations as
written below:
∫ ∫ ∫
Ω Ω
∂
∂
∂
∂
−
∂
∂
= Ω 
¹

\

∂
∂
∂
∂
dz dy dx
x
N
x
T
K dz dy
x
T
K N d N
x
T
K
x
i
z y
i i
. . .
,
∫ ∫
Ω Γ
Ω
∂
∂
∂
∂
− Γ
∂
∂
= d
x
N
x
T
K d
x
T
K N
i
i
∫ ∫ ∫
Ω Ω
∂
∂
∂
∂
−
∂
∂
= Ω


¹

\

∂
∂
∂
∂
dz dy dx
y
N
y
T
K dz dx
y
T
K N d N
y
T
K
y
i
z x
i i
. . .
,
∫ ∫
Ω Γ
Ω
∂
∂
∂
∂
− Γ
∂
∂
= d
y
N
y
T
K d
y
T
K N
i
i
∫ ∫ ∫
Ω Ω
∂
∂
∂
∂
−
∂
∂
= Ω 
¹

\

∂
∂
∂
∂
dz dy dx
z
N
z
T
K dy dx
z
T
K N d N
z
T
K
z
i
z x
i i
. . .
,
40
∫ ∫
Ω Γ
Ω
∂
∂
∂
∂
− Γ
∂
∂
= d
z
N
z
T
K d
z
T
K N
i
i
Thus, the equation (4.2) becomes;
0 = Ω


¹

\

∂
∂
∂
∂
+
∂
∂
∂
∂
+
∂
∂
∂
∂
− Γ
∂
∂
+ Γ
∂
∂
+ Γ
∂
∂
∫ ∫ ∫ ∫
Ω Γ Γ Γ
d
z
N
z
T
y
N
y
T
x
N
x
T
K d
z
T
K N d
y
T
K N d
x
T
K N
i i i
i i i
(4.3)
Let q
x,
q
y,
and
q
z
be the
heat flux in x, y and z direction respectively and can be written as:
x
T
K q
x
∂
∂
− = ,
y
T
K q
y
∂
∂
− = and
z
T
K q
z
∂
∂
− =
Putting these values of q
x
, q
y
, q
z
in equation (4.3), we have:
( ) 0 = Ω


¹

\

∂
∂
∂
∂
+
∂
∂
∂
∂
+
∂
∂
∂
∂
− Γ + + −
∫ ∫
Ω Γ
d
z
N
z
T
y
N
y
T
x
N
x
T
K d n q n q n q N
i i i
z z y y x x i
(4.4)
Where, n
x
, n
y
, n
z
are the direction cosines of unit normal to the surfaces.
And, let
z z y y x x n
n q n q n q q + + =
Therefore equation (4.4) becomes,
∫ ∫
Ω Ω
= Ω


¹

\


¹

\

∂
∂
∂
∂
+


¹

\

∂
∂
∂
∂
+ 
¹

\

∂
∂
∂
∂
− Γ − 0 d
z
N
z
T
y
N
y
T
x
N
x
T
K d q N
i i i
n i
(4.5)
Here,
n
q is normal heat along the unit outward normal, which is specified by
boundary conditions.
Now the heat flux in the tool is because of the heat load at the specified contact of
tool and workpiece, and heat loss because of convection at the other surfaces of the tool
exposed to air/coolant.
Thus, ( ) ( ) ( )
∫ ∫ ∫
Γ − + Γ = Γ
∞
d T T h N d N q d q N
i i o n i
(4.6)
From equations (4.5) and equation (4.6), the final FEM equation has been
developed, as written below:
41
( ) 0 = Ω
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
− Γ − − Γ −
∫ ∫ ∫
Γ
∞
Γ
d
z
T
y
T
x
T
z
N
y
N
x
N
K d T T h N d N q
i i i
i i o
(4.7)
1 2 3
Explanation of each part of above equation (4.7) is as given below:
1. The first part of equation (4.7) is represented { }
q
R ,which represents heat load vector
arising from specified surface heating
{ }  
∫
Γ
Γ − = d N q R
T
o q
[N]
T
=
4
3
2
1
N
N
N
N
Where, N
i
=, N
1
, N
2
, N
3
, N
4
, are shape functions
Γ Represents surface area A
Further, vector {R
q
} can also be written as
{ } dA N q R
T
o q
] [
1
1
1
1
∫ ∫
+
−
+
−
=
Here, dA=det J η ξd d
η
Where
( ) 4 1
1
ηξ ξ η + − − = N
( ) 4 1
2
ηξ ξ η + + − = N
ξ
( ) 4 1
3
ηξ ξ η − + + = N
( ) 4 1
4
ηξ ξ η − − + = N
(1, 1) (1, 1)
(1,1) (1,1)
42
Jocobian matrix also represented as [J], which can be expanded as given below
 
∂
∂
+ +
∂
∂
∂
∂
+ +
∂
∂
∂
∂
+ +
∂
∂
∂
∂
+ +
∂
∂
∂
∂
+ +
∂
∂
∂
∂
+ +
∂
∂
∂
∂
+ +
∂
∂
∂
∂
+ +
∂
∂
∂
∂
+ +
∂
∂
=
8
8
1
1
8
8
1
1
8
8
1
1
8
8
1
1
8
8
1
1
8
8
1
1
8
8
1
1
8
8
1
1
8
8
1
1
... ... ...
... ... ...
... ... ....
z
N
z
N
y
N
y
N
x
N
x
N
z
N
z
N
y
N
y
N
x
N
x
N
z
N
z
N
y
N
y
N
x
N
x
N
J
ζ ζ ζ ζ ζ ζ
η η η η η η
ξ ξ ξ ξ ξ ξ
Finally {Rq} equation written as below,
{ }  
∫ ∫
− −
=
1
1
1
1
] [ η ξ d d J N q R
T
o q (4.8)
2. Second part of the equation (4.7) can be further expressed in two separate parts as
written below:
( )
∫ ∫ ∫
Γ
∞
Γ Γ
∞
Γ + Γ − = Γ − − d hT N hTd N d T T h N
i i i
Where, h = convective heat transfer coefficient
∞
T = convective exchange temperature of air/fluid.
T = unknown surface temperature.
The first part of above equation is heat load vector arising from surface convention
and denoted as { }
h
R
{ }
∫
Γ
∞
Γ = d T h N R
i h (4.9)
Now vector {R
h
} can further be written as:
{ }  
∫ ∫
− −
∞
=
1
1
1
1
η ξ d d J T h N R
T
h
43
Second part represents element conduction matrix related to convention and represented
as:
 { }
∫
Γ
Γ − = d T h N T k
i h
Here, [K
h
] = Element Conductance Matrix related to Convection,
{T} = Element Nodal Temperature Vector.
Where, T=
∑
=
8
0 i
i i
T N
Or, T = N
1
T
1
+N
2
T
2
+………………+ N
8
T
8
Putting this in above equation,
Thus we have,
     
∫ ∫
− −
=
1
1
1
1
η ξ d d J N N h K
T
h (4.10)
3. The third part of equation (4.7) is the element conductance matrix related to the
conduction (coefficient matrix). It is represented by   { } T K
c
Where,
 { }
∫
Ω
Ω
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
= d
z
T
y
T
x
T
z
N
y
N
x
N
K T K
i i i
c
(4.11)
Temperature gradient within the element is given by
8
8
3
3
2
2
1
1
....... .......... T
x
N
T
x
N
T
x
N
T
x
N
x
T
∂
∂
+
∂
∂
+
∂
∂
+
∂
∂
=
∂
∂
(4.11a)
8
8
3
3
2
2
1
1
....... .......... T
y
N
T
y
N
T
y
N
T
y
N
y
T
∂
∂
+
∂
∂
+
∂
∂
+
∂
∂
=
∂
∂
(4.11b)
8
8
3
3
2
2
1
1
....... .......... T
z
N
T
z
N
T
z
N
T
z
N
z
T
∂
∂
+
∂
∂
+
∂
∂
+
∂
∂
=
∂
∂
(4.11c)
44
In matrix form, the above relations can be represented as:
∂
∂
∂
∂
∂
∂
z
T
y
T
x
T
=
8 3
8 2 1
8 2 1
8 2 1
.......... .......... .......... .......... ..........
.......... .......... .......... .......... ..........
.......... .......... .......... .......... ..........
×
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
z
N
z
N
z
N
y
N
y
N
y
N
x
N
x
N
x
N
1 8
8
7
6
5
4
3
2
1
×
T
T
T
T
T
T
T
T
Using the above relations equation (4.11) can be written as
 
∫ ∫ ∫
− − −
=
1
1
1
1
1
1
ζ η ξ d d d J B B K K
T
c
(4.12)
Where B matrix is given as
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
=
z
N
z
N
z
N
y
N
y
N
y
N
x
N
x
N
x
N
B
8 2 1
8 2 1
8 2 1
... ...
... ...
... ...
T
B is the transpose of B matrix.
To achieve the close boundary representation the scientists have developed
curvilinear side element based on transforming simple geometric shapes of some local
coordinate system into distorted shapes in global Cartesian system and then evaluating
the element equation for the distorted element. The parent element may be selected from
lagrangian / serendipity family. The Local Coordinate System associated with parent
element is called curvilinear coordinate.
The Serendipity coordinates for elements are represented as:
∑
=
=
c
n
i
i i
x M x
1
45
∑
=
=
c
n
i
i i
y M y
1
∑
=
=
c
n
i
i i
z M z
1
Here, n
c
= Total number of nodes per element
and for isoparametric elements, M
i
= N
i
Therefore,
∑
=
=
8
1 i
i i
x N x
∑
=
=
8
1 i
i i
y N y
∑
=
=
8
1 i
i i
z N z
Here, N
i
is a function of ( ζ η ξ , , ).
Now to evaluate the B–matrix we need to evaluate the derivative of shape function
with respect to x, y and z. The derivative cannot be found out directly as shape function is
expressed in terms of natural coordinates ( ζ η ξ , , ). So by using chain rule
differentiation
ξ ξ ξ ξ ∂
∂
∂
∂
+
∂
∂
∂
∂
+
∂
∂
∂
∂
=
∂
∂ z
z
N y
y
N x
x
N N
i i i i
. . .
η η η η ∂
∂
∂
∂
+
∂
∂
∂
∂
+
∂
∂
∂
∂
=
∂
∂ z
z
N y
y
N x
x
N N
i i i i
. . .
ζ ζ ζ ζ ∂
∂
∂
∂
+
∂
∂
∂
∂
+
∂
∂
∂
∂
=
∂
∂ z
z
N y
y
N x
x
N N
i i i i
. . .
∂
∂
∂
∂
∂
∂
ζ
η
ξ
i
i
i
N
N
N
=
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
∂
ζ ζ ζ
η η η
ξ ξ ξ
z y x
z y x
z y x
∂
∂
∂
∂
∂
∂
z
N
y
N
x
N
i
i
i
The final heat transfer equation can be written as
      { } { }
h h c
R T K K = +
46
The above equation can be further written in the form as given below
 { } { } Q T K =
(4.13)
Where
[K] = Thermal conductance coefficients matrix
{T}= Nodal temperature vector.
{Q}= Nodal heat flux or heat load vector.
4.4 HARDNESS OF TOOL
Since effects of temperature are being considered on flank wear, so it becomes
necessary to consider thermal softening of cutting tool material. Relationship between
temperature and thermal softening can be given by [18]
4 3
2
2
3
1
) ( C T C T C T C T H + + + =
Where H is hardness of cutting tool material, T is temperature in
o
C and C
1
, C
2
, C
3
,
and C
4
are constants for tool material.
For carbides tool the values for these are:
C
1
= 0.000006, C2
= 0.0054, C
3
= 0.5853, C4=1517
4.5 SOLUTION SCHEME
• The threedimensional solution domain corresponding to tool bit is discredited for the
solution of the final heat conduction equation (4.13) and appropriate boundary
conditions are applied.
• The value of elemental matrices [Kc] and [Kh] are calculated in functions stiff( ) and
convection_stiff( ) and they are added appropriately to find L.H.S. of the equation
4.10 and 4.12 respectively.
• The [Rh] matrix is calculated as per equation in function load( )
• Appropriate boundary condition are applied in boundary( ) and then the global {T}
vector is calculated from function solver( ).
• The function separate( ) gives the values of {T}, which are thus used in function
hardness( ) to calculate the value of hardness at different nodes.
47
4.6 FLOW CHART OF SOLUTION PROCEDURE
START
Call data( ), h_data( )
Read 3D mesh data and boundary
condition
Call stiff( )
Generate [Kc] matrix equation (2)
Call connection_stiff( )
Generate stiffness matrix due to
convection boundary condition
Call load( )
Generate R.H.S of equation (vector {R
h
})
Call boundary( )
Call solver( )
Call separate( )
Call Hardness( )
STOP
48
CHAPTER  5
RESULTS AND DISCUSSIONS
In the present chapter the results for the present problem, that is for the solution of
the thermal softening of the tool material in order to predict the tool wear have been
developed in accordance with the previously developed models for tool wear [4], [20]
and [22]. The number of experiments has been conducted to find out the cutting forces
and flank wear of the tool, made of tungsten carbide, at varying machining parameters,
which are cutting speed (V), cutting feed (f) and depth of cut (d). Using the experimental
data, the strain rate and average interface temperature for the various cutting conditions
have been obtained, which have been ultimately used to determine the modified
temperature at the tool and the workpiece contact area. The measured experimental
values are than fed into the FEM program to predict the temperature at all the nodes of a
cutting tool. For simplicity the tool is assumed to be a single point with zero nose radius.
This temperature of contact area have been used to determine the overall temperatures at
the various parts of the cutting tool using the heat transfer equation developed and using
the FEM methods for the solution of these equations for the present problem with the
appropriate boundary condition as has been explained in chapter 4. This predicted
temperature is than related with the hardness of the cutting tool (Thermal softening).
5.1 MACHINING PARAMETERS USED FOR EXPERIMENTATION
Table 5.1: Cutting parameters
Cutting speed v (rpm)
(Range)
Feed f (mm/rev)
(Range)
Depth of cut d (mm)
(Range)
420 0.08 0.5
710 0.16 0.75
The table 5.1 shows the numerical values of the various machining parameters
(cutting speed, feed and the depth of cut), that have been selected for experimentation, for
the measurement of the temperature, strain rate and flank wear. The EN24 steel
workpiece material has been used for experimentation, and its specifications have been
49
shown in appendix B. The cutting material used is Tungsten Carbide, and its specification
has been mentioned in appendix C.
The table 5.2 shows the experimental values of wear, strainrate and resultant
cutting forces for different speed, feed and depth of cuts for the different set of
experiments conducted on the carbide cutting tool. The levels of the process variables,
which have been used for the experiments of the validation set, are in between the [1, 1]
range. Here, 1 stands for the minimum, and +1 stands for the maximum level of
parameters.
Table 5.2: Experimental Results of measured parameters against parameters V, f and d
S. No. v d f
Wear(exp)in
mm
Strain
Rate(exp)
1s
1
Resultant
Forces (N)
1 1 1 1 0.02 577 340
2 1 1 +1 0.025 569 410
3 1 +1 1 0.03 165 470
4 1 +1 +1 0.035 550 560
5 +1 1 1 0.045 840 245
6 +1 1 +1 0.05 880 500
7 +1 +1 1 0.065 820 390
8 +1 +1 +1 0.075 830 398
To eliminate the effect of wear on the experiments, the tools have been replaced
after every cut of constant volume of workpiece material. In total eight carbide bits have
been used for all the different set of experiments to be conducted. Tool edge has been
made straight or parallel to the chuck to have an orthogonal cut. Constant volume
signifies that equal amount of material was removed in all the different sets of experiment
conducted. This has been done so that all the measurements should be taken correctly at
the same operating conditions to have a good accuracy in results with minimum possible
error.
The relationship between machining parameters and temperature generated at tool
workpiece interface has been calculated using the empirical relations as mentioned in the
references [4], [24], and [26]. The temperature at tool tip was calculated by changing
different depth of cut, feed rate and cutting velocity. Strain rate has also been measured
using the empirical relations and than both the measured temperature and the strain rate
50
are put into the equation to find the modified temperature which considers the effect of
both.
This temperature has been applied to analyze the temperature distribution on the
tool at different edge, nodes and elements through finite element analysis, considering
heat loss because of conduction in the tool material and convection with air at ambient
temperature. Tool material hardness has been calculated with the help of the temperature
distribution obtained as a result of FEM analysis [18]. The results have been obtained for
tool wear with the change in machining parameters by relating the heat generated at the
toolworkpiece interface and taking hardness of tool material as a function of temperature
[18].
5.2 MODELLING OF SOLUTION DOMAIN USING FEM
In order to use the finite element technique, mathematical expressions have been
derived and discussed in the previous chapter and have been used to predict the
temperature at the various locations of the cutting tool. Computer program in VC
++
environment based on the FEM formulation presented in the previous chapter have been
developed and numerical results for temperature and its effect on the hardness of the
cutting tool have been obtained and discussed in preceding topics.
The following are the details of the discritization of the solution domain carried
out for the FEM Analysis and thus used in the developed computer program for the
generation of the results.
Problem is for : 3 D heat conduction
Type of elements : Eight Noded brick elements (Serendipity family)
Total node : 288
Total element : 168
Node per element : 8
Node per face : 4
Number of fixed nodes : 3 (temperature at the tip of the cutting tool)
Number of convection Faces : 6 (shown in Appendix–C)
51
The properties of the cutting tool used (Carbide bits) are:
18 . 0 = ν ,
1
.
1
−
= s γ ,
∞
T =27
o
C (for air), K = 0.076 W/m
2
k
5.3 VALIDATION OF RESULTS
Figure 5.1: Relationship between Cutting tool temperature and flank distance
In order to check the validity of the analysis and the solution procedure discussed
in chapter 4, the results for temperature field and its effect on thermal softening of cutting
tool have been obtained from the developed computer program by using the experimental
data of strainrate and flank wear, and have been compared with the results of Leshock et
al [4], for checking the validity of the results. The relation between flank edge distance
and the final temperature variation on the cutting tool have been developed for the range
of the cutting parameters as given in the table 5.1, and have been shown here in
graphically form in figure 5.1. It is interpretable from the graph, that as we move away
from the flank edge, the temperature keeps on decreasing and thus the tip of the carbide
cutting tool is prone to more wear rather than the distances away from the tool tip. The
results from the reference are well in accordance with the results of the present work, as
the maximum variation in the results is only of the order of 5.8 %.
5.4 VARIATION OF HARDNESS WITH FLANKEDGE DISTANCE
The figure 5.2 shows the relation of tool hardness with the flank distance at
different temperature distribution on flank edge of the carbide tool bit. As at the tool tip
the temperature is maximum, therefore the hardness is less. Using the mathematical
model for modified cutting temperature as discussed in section 4.2, the three different
values of modified cutting temperatures 750 K, 900 K, and 1050 K, have been calculated
52
from the corresponding strainrate values which are 840 s
1
, 830 s
1
, and 577 s
1
respectively, corresponding to the different values of feed, speed and depth of cut as
shown in table 5.1. At the same flankedge distance, for these values of modified cutting
temperatures, we have different hardness values along the flank face of the tool. The
temperature starts decreasing because of heat loss as we move away from the tool tip
along the flank surface the hardness of material increases.
0
200
400
600
800
1000
1200
1400
1600
0.00 0.50 1.00 1.50 2.00 2.50
Flank Edge Distance (mm)
H
a
r
d
n
e
s
s
(
B
H
N
)
Temp. at tip = 1050
Temp at tip = 900
Temp at tip = 750
Figure 5.2: Relation between hardness and flank distance
5.5 VARIATION OF TEMPERATURE WITH CUTTING FORCE
0
200
400
600
800
1000
1200
1400
200 300 400 500 600 700
Resultant Force(N)
T
e
m
p
e
r
a
t
u
r
e
s
(
o
K
)
Temperature (K)
Mod. Temp. (K)
Figure 5.3: Variation of Temperature with resultant cutting force
The figure 5.3 shows the variation of temperature with the cutting force. As
shown in the graph, as the cutting forces increases the temperature at the tip of the cutting
tool also increases due to higher frictional forces at the tip of the carbide tool bit. This
53
increased temperature of the tool leads to the reduction of hardness value of the cutting
tool and thus the tool wear.
5.6 VARIATION OF FLANK WEAR WITH CUTTING FORCE
Figure 5.4: Variation of Flank Wear with the resultant cutting force
The figure 5.4 shows the variation of the wear with the cutting tool Force. As
shown the flank wear of carbide insert increases with the increase in the forces during the
bar turning process. This is because increase in forces leads to increase in the temperature
of the cutting tool as shown in figure 5.3 and increased temperatures further leads to the
flank wear of the cutting tool due to the thermal softening.
5.7 VARIATION OF FLANK WEAR WITH MODIFIED CUTTING
TOOL TEMPERATURE
Figure 5.5: Variation of flank Wear with respect to modified temperature
54
The figure 5.5 shows the variation of the wear with the modified cutting tool
temperature due to the strain rate. As shown the flank wear of carbide insert increases
with the increase in the temperature of the cutting tool. As increased temperatures at the
tip of the cutting tool leads to the reduction of the hardness value, that is the thermal
softening, and thus to the flank wear of the carbide cutting tool.
5.8 REGRESSION EQUATION
Regression equations obtained from the experimental data of a bar turning process
using carbide insert were obtained using Data Fit software Version8.0.x developed by
Oakdale Engineering. The regression equation relating tool flank wear of a carbide insert
with cutting parameters (V, f, d) is as follows.
D) f C d B f (A
e (mm) Wear
+ × + × + ×
=
15 16 15
e 1.612 D , e 2.015 C , e 6.44  B 1.045, A × = × = × = =
Where v, f and d are levels of cutting speed (v), feed (f) and depth of cut (d)
respectively and values for these levels can be obtained by following Formula:
level) middle and maximum Between e (Differenc
range) the of mean value  range in the value (actual
Level =
5.9 VARIATION OF TEMPERATURE WITH CUTTING VELOCITY
0
200
400
600
800
1000
1200
1400
1.50 1.00 0.50 0.00 0.50 1.00 1.50
Cutting Velocity at f 1
T
e
m
p
e
r
a
t
u
r
e
(
K
)
d = 1
d = +1
Figure 5. 6: Relation between Cutting velocity and temperature at feed rate (f = 1)
55
The figure 5.6 shows a relation of cutting velocity versus temperature, at constant
feed at different levels depth of cuts used in experimentation work. The inference that can
be drawn from the above graph is that when we increase the cutting velocity the
temperature keeps on increasing.
Figure 5.7: Relation between Cutting velocity and temperature at feed rate (f = +1)
The figure 5.7 depicts the same trends as figure 5.6, from these trends it’s
depicted that with the increase in velocity of cutting, the temperature raises. These two
graphs are at constant depth of cuts for each curve. The figure 5.8 shows results of
temperature with cutting velocity at constant depth of cuts. It shows temperature increase
with increase in depth of cut.
Figure 5.8: Variation of Temperature versus cutting velocity at depth of cut (d = 1)
56
500
600
700
800
900
1000
1100
1200
1300
1400
1.50 1.00 0.50 0.00 0.50 1.00 1.50
Cutting Velocity at d =+1
T
e
m
p
e
r
a
t
u
r
e
(
k
)
f = 1
f = +1
Figure 5.9: Variation of Temperature versus cutting velocity at depth of cut (d = +1)
Similarly figure 5.9 shows the graph but at different machining parameters and
conditions (d = +1). The trend line is depicted to be same as it increases with rise in
velocity of cutting.
5.10 VARIATION OF FLANK WEAR WITH CUTTING VELOCITY
(FOR CONSTANT FEED RATE)
Figure 5.10: Variation of flank wear with cutting velocity at constant feed rate (f = 1)
Here the results have been shown for the variation of wear with the cutting
velocity of the tool. In figure 5.10 trend of cutting velocity with wear has been shown at
constant feed of 1, that is the lowest feed taken in experiments at different depth of cuts
57
shows almost same pattern of increasing flank wear with increase in velocity. The figure
5.11 depicts same trends of wear but here now feed rate is (f = +1). The results seem
almost similar for this case too.
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
1.50 1.00 0.50 0.00 0.50 1.00 1.50
Cutting velocity at f =+1
F
l
a
n
k
w
e
a
r
(
m
m
)
d = 1
d = +1
Figure 5.11: Variation of flank wear with cutting velocity at constant feed rate (f= +1)
5.11 VARIATION OF FLANK WEAR WITH CUTTING VELOCITY
(FOR CONSTANT DEPTH OF CUTS)
The graphs discussed till now were at constant feed rate, for better understanding
of wear trends graphs are also shown at constant depth of cuts. The figure 5.12 shows
results of wear with cutting velocity at constant depth of cuts.
0
0.005
0.01
0.015
0.02
0.025
0.03
0.035
0.04
1.50 1.00 0.50 0.00 0.50 1.00 1.50
Cutting velocity at d=1
F
l
a
n
k
w
e
a
r
(
m
m
)
f = 1
f = +1
Figure 5.12: Variation of flank wear with cutting velocity at constant depth of cut (d = 1)
58
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
1.50 1.00 0.50 0.00 0.50 1.00 1.50
Cutting velocity at d=+1
F
l
a
n
k
w
e
a
r
(
m
m
)
f = 1
f = +1
Figure 5.13: Variation of flank wear with cutting velocity at constant depth of cut (d =+1)
The figure 5.13 also shows similar results but at depth of cuts (d = +1). The trend
is almost same depicted in other graphs as shown before, that is with increase in the
cutting velocity for some constant value of depth of cut, the tool wear increases.
5.12 CONCLUSIONS
Based on the results presented in previous sections, the following conclusions
have been observed:
1. The hardness increases with increase in distance from the flank edge and with
decrease in the toolworkpiece contact temperature.
2. The change in the tool workpiece contact temperature depends upon the cutting
parameters and it increases with increase in resultant cutting force, but do not follow a
linear trend and thus we can find an optimum set of machining parameters to have a
minimum heat generation at toolworkpiece contact.
3. The flank wear is directly proportional to the resultant cutting force and
approximately follows a linear trend.
4. The flank wear increases with increase in modified cutting tool temperature (due to
increase in the strain rate), but there is a nonlinear trend so we can find an optimum value
of cutting parameters so as to give minimum strain rate, because heat generated increases
with increase in the strain rate.
5. The contact temperature increases with the increase in the cutting velocity, but at
constant cutting velocity, there is a significant increase in the contact temperature with
59
increase in the depth of cut as compared to the increase in the contact temperature with
the increase in the feed rate.
6. The flank wear increases significantly with the increase in the cutting velocity. Also
at constant cutting speed it increases with increase in both feed rate and depth of cut.
Thus finally it can be observed that we must select the cutting parameters, which
are cutting speed, feed rate, and depth of cut, in such a way so as to have the optimum
temperature at the tool tipworkpiece contact because of the heat generated, so that the
minimum tool wear is encountered, and thus we could have the longest tool life and
better machining economy.
5.13 SCOPE FOR FURTHER WORK
With increasing competitiveness as observed in the recent times, manufacturing
systems in the industry are being driven more and more aggressively. So there is always
need for perpetual improvements. Thus for getting still more accurate results we can take
into account few more parameters as given below:
• The transient analysis for the machining operation can be studied.
• The study can also be extended on coated carbide tools, CBN, or other harder tools.
• CNC machines can be used for the experimentation to have the better control of the
process variables and also parameters can be set to the desired accuracy.
• The presently developed system can be used for other conventional as well as
unconventional processes such as milling, drilling.
• The other combinations of machine, cutting tool and work material can be studied.
60
APPENDIX  A
SPECIFICATIONS OF THE CENTRE LATHE
Center Height 200 mm
Center Distance 1000 mm
Swing
Over Bed 420 mm dia
Over Cross slide 220 mm dia
In Gap 550 mm dia
Gap Width 155 mm dia
Transverse
Of Cross slide 225 mm
Of Top 125 mm
Of Tailstock Spindle 150 mm
Spindle Bore 53 mm dia
Spindle Bore Taper Metric Short No. 7
Spindle Speed 321200 rpm
Spindle Speed Ratio 1.69
Tool Shank Size 25x25, 20x20 mm
Feed
Longitudinal Feeds 0.052.7 mm/rev
Cross Feed 0.010.54 mm/rev
Main Motor 2.2KW/3 HP
Weight of Machine 1250 Kg
Height of the Spindle Center above Floor 1035 mm
Floor Space 915x2725 mm
3 Phases, 415 V, 50 Hz, AC Supply
61
APPENDIX –B
WORKPIECE SPECIFICATIONS
• Work piece material : EN 24steel
• Work piece combination : 0.35 0.45 %C
0.45 0.6 %Mn
1.3  1.8 %Ni
0.9  1.4 % Co
0.2  0.3 % Cr
0.1  0.35% Si
And rest is Iron
• Work piece hardness : 260BHN
• Cutting tool material : K10 CARBIDE INSERT
• Hardness : 1500 BHN
62
6
5
3
1
2
4
APPENDIX – C
WORKPIECE SPECIFICATIONS
Figure AC.1: Convection faces used in FEM analysis of Carbide cutting tool
Here 1, 2, 3, 4, 5, 6 are the faces through which the heat is lost to the environment
(convection heat loss).
63
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[5] Mills B., Hao C.S., Qi H.S., “Formation of an adherent layer on a cutting tool
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pp. 6166.
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[7] Chu T.H., Wallbank J., “Determination of the temperature of a machined
surface”, Journal of Manufacturing Science and Engineering, vol.120 (1998), pp.
259263.
64
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[12] Sullivan D.O., Cotterell M., “Temperature measurement in single point turning”,
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[14] Huda Mahfudz Al, Yamada Keiji, Hosokawa Akira, Ueda Takashi, “Investigation
of Temperature at ToolChip Interface in Turning Using TwoColor Pyrometer”,
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[18] Zhao H., Barber G.C., Zou Q., “A study of flank wear in orthogonal cutting with
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65
[19] Yen YungChang, Sohner Jorg, Lilly Blaine, Altan Taylan, “Estimation of tool
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[24] Sinha Aman, “Condition monitoring of tool and workpiece in turning using neural
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[25] Chou Kevin Y., Song Hui, “Thermal modeling for white layer predictions in
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[29] Sharma Gagnesh, “Analysis of a Carbide Insert for Flank Wear monitoring during
66
Turning using Finite Element Method”, M Tech thesis, Department of Mechanical
Engg. TIET, Patiala, India 2004.
CERTIFICATE
This is to certify that the seminar entitled “ Thermal Modeling & Analysis of Carbide Tool Using Finite Element Method ”, being submitted by Mr. Amit Gupta in partial fulfillment of the requirements for the award of the degree of Master of Engineering (CAD/CAM & Robotics Engineering) at Thapar Institute of Engineering and Technology (Deemed University), Patiala (INDIA) is a bonafide work carried out by him under our guidance and supervision and that no part of this thesis has been submitted for the award of any other degree .
(Mr. Gaurav Bartarya) Lecturer, MED T.I.E.T. Patiala147004(PUNJAB)
(Mr. Ravinder Kumar Duvedi) Lecturer, MED T.I.E.T. Patiala147004(PUNJAB)
(Dr. S. K. Mohapatra) Professor& Head, MED T.I.E.T. Patiala147004(PUNJAB)
(Dr. D. S Bawa) Dean Academic Affairs T.I.E.T. Patiala147004(PUNJAB)
2
ACKNOWLEDGEMENT
I express my sincere gratitude to my guide, Mr. Gaurav Bartarya, and Mr. Ravinder Kumar Duwedi, Mechanical Engineering Department, Thapar Institute of Engineering & Technology for his valuable guidance, proper advice, and careful reviews of my work at all stages, and their highly appreciated instruction and constant encouragement during the course of my work on this thesis. I am highly thankful to Dr. Vijay Jadon, Asst. Prof., Mechanical Engineering Department, Thapar Institute of Engineering and Technology, Patiala for his expert advice, technical suggestions and moral support during my thesis work. Especially, I want to express my deepest appreciation and thanks to my supervisor Mr. Sukhdev Chand for his support and untiring help in conducting my experiments. I do not find enough words with which I can express my feeling of thanks to all my teachers and friends at T.I.E.T., for their help, inspiration and moral support which went a long way in completion of my thesis. I am also thankful to the authors whose works I have consulted and quoted in this work. I also extend my thanks to all faculty and staff members of Mechanical Engineering Department, Thapar Institute of Engineering and Technology, for their direct and indirect help and cooperation.
(Amit Gupta)
3
has been an active area of research for quite a long time. The accurate prediction of tool wear is important to have a better product quality and dimensional accuracy.ABSTRACT The problem of tool wear monitoring in machining operations. The results prescribed demonstrate the significance of cutting parameters (speed. feed and depth of cut) in thermal analysis for study of the cutting tool wear. The results obtained have been verified with the available results from literature for the variation of wear with the temperature and thermal softening of carbide tool. 4 . if improvements in tool performance are to be achieved The present work involves the study of tool wear caused by the change in hardness of single point cutting tool for a turning operation to predict the tool life in orthogonal cutting based on the heat transfer analysis using Finite Element Method (FEM). The results reveal that by increasing process variables in machining the wear and temperature increases causing thermal softening of tool causing it to wear. An empirical relation is used to determine temperature at tooltip and further Finite Element Method is used to determine the distribution of temperature over the surface of tool and its impact on hardness which is related by an empirical relations. The study shows the effect of Modified temperature due to strain rate on carbide tool to describe the thermal softening of tool material and becomes prone to wear. The Experiments were performed with EN24 steel as workpiece and Carbide uncoated tool bit as a tool material and the flank wear has been measured experimentally. In cutting tools the area close to the tool tip is the most important region and conditions at the tool tip must be carefully examined.
1 Instrumentation 3.2.1.INDEX CONTENTS NOMENCLATURE LIST OF FIGURES LIST OF TABLES CHAPTER 1: Introduction 1.2 Experimentation 3.2 Application of FEM for tool wear research 2.1 Tool Wear 1.2.3.3 Thermal analysis 1.3.4 Tool Wear Models 1.2 Wear Mechanism 1.2.1.1.1 Heat Generation in Machining 1.1 Consequences of tool wear 1.2.1.3 Experiment Methodology 26 2627 2728 2426 1112 1213 13 14 14 1523 1517 1723 23 2428 1011 11 24 46 68 810 PAGE NO.5 Finite Element Method in Thermal Analysis CHAPTER 2: LITERATURE REVIEW 2.1 Models for determination of temperature field 2.2.14 5 .2 Experimental procedure 3.4 Heat Effects 1.2 Effects of the tool wear on technological performance 1.3 Summary of Literature CHAPTER 3: INSTRUMENTATION AND EXPERIMENTATION 3.3 Prediction of Tool Wear 1.3.2 Characteristics of tool wear 1. (i) (ii) (iii) 1 .2 Analysis Techniques 1.1.3.1 Planning of experiment 3.1 Tool Wear Phenomena 1.3 Heat Transfer in Machining 1.1 Force measurement 3.3.
3 Validation of results 5.10 Variation of Flank Wear with Cutting Velocity (for Const.6 Variation of Flank Wear with Cutting Force 5.5 Solution Scheme 4.9 Variation of Temperature with Cutting Velocity 5.7 Variation of Flank Wear with Modified Cutting Tool Temperature 5.3 FEM formulation 4. feed rate) 2938 29 2930 3037 37 37 38 3950 3941 4142 42 4243 4344 44 4445 45 4547 4748 5.8 Regression Equation 5.4 Hardness of tool 4.12 Conclusions 5.CHAPTER 4: ANALYSIS 4.11 Variation of Flank Wear with Cutting Velocity (for Const.1 Governing equation for the heat transfer 4.13 Scope for Further Work 49 50 APPENDIX A APPENDIX B APPENDIX C 51 52 53 REFERENCES 5457 6 .6 Flow chart of Program CHAPTER 5: RESULTS AND DISCUSSIONS 5.5 Variation of Temperature with Cutting Force 5.4 Variation of Hardness with FlankEdge Distance 5.1 Machining parameters used for experimentation 5.2 Boundary condition 4.2 Modeling of solution domain using FEM 5.depth of cuts)4849 5.
Γ : Local coordinates : Solution Domains : Conductivity coefficient : Convection coefficient : Cutting velocity : Depth of cut : Feed rate : Shear Angle : Rake Angle : Internal heat : Strain Rate K h V d f φ α Q .NOMENCLATURE DIMENSIONAL PARAMETERS X . : Reference Strain Rate : Poisson’s Ratio ν MATRICES AND VECTORS [J ] [N ] [K c ] [K h ] {Rh } : Jacobian matrix : Shape function matrix : Conductivity matrix : Convection matrix : Convection load vector : Heat flux load vector : Nodal pressure vector {R } q {T } 7 (i) .η Ω. Z : Cartesian coordinate system ξ . Y . γ γo .
VB the flank wear and θ is the relief angle Fig 3.2: Behaviour of Flank wear Fig 1.2 Relation between hardness and flank distance Fig 5.7 Relation between Cutting velocity and temperature at feed rate (f = +1) Fig 5.13 Variation of flank wear with cutting velocity at constant depth of cut (d = +1) 49 FigAC.8 Variation of Temperature versus cutting velocity at depth of cut (d = 1) Fig 5.1: Types of Tool Wear Fig 1.6 Relation between Cutting velocity and temperature at feed rate (f = 1) Fig 5.10 Variation of flank wear with cutting velocity at constant feed rate(f = 1) Fig 5.LIST OF FIGURES Fig 1.4.2 Dynamometer Fig 3. where w is the Tool widths.3 Variation of Temperature with resultant cutting force Fig 5.3 Dimensions of the workpiece Fig 3.5 Variation of flank Wear with respect to modified temperature Fig 5.5: Zones of heat generation & dissipation during the metal cutting process Fig 2.1 Convection faces used in FEM analysis of Carbide cutting tool 53 8 (ii) .4 Variation of Flank Wear with the resultant cutting force Fig 5.9 Variation of Temperature versus cutting velocity at depth of cut (d = +1) Fig 5.12 Variation of flank wear with cutting velocity at constant depth of cut(d = 1) 48 Fig 5.1 Wheatstone bridge Fig 3.4: Influencing elements of tool wear Fig 1. machining Fig 5.3: Wear mechanisms Fig 1.1 Model of chip formation used in Oxley’s analysis for Orth.4 Schematic diagram of the lathe and equipment setup Fig.1 Relationship between Cutting tool temperature and flank distance Fig 5.1: Schematic of cutting tool with zero degree rake angle.11 Variation of flank wear with cutting velocity at constant feed rate(f= +1) 21 25 25 27 28 29 42 43 43 44 44 45 46 46 47 47 48 3 3 6 7 12 Fig 5.
LIST OF TABLES Table 1.1 Tool life and Tool wear rate models Table 5. f and d 40 9 (iii) .1 Cutting parameters 9 39 Table 5.2 Experimental Results of measured parameters against parameters V.
e. tool life and machining cost. mechanical breakage. and tool brittle fracture or due to the rise in the interface temperatures. increasing cutting force. At present. They create about 15% of the value of all mechanical components manufactured worldwide. cutting edge blunting. it gives only the information about tool life. The life of the cutting tool comes to an end. cutting speed. and is very easy to use.1 INTRODUCTION Tool wear monitoring/sensing should be one of the primary objectives in order to produce the required end products in an automated industry so that a new tool may be introduced at the instant at which the existing tool has worn out. Then the cutting tool must be replaced or ground and the cutting process is interrupted. This can be achieved only through optimal utilization of both material and human resources. Tool wear influences cutting power. thus preventing any hazards occurring to the machine or deterioration of the surface finish. vibration and cutting temperature cause surface integrity deteriorated and dimension error greater than tolerance. But capability of predicting the contributions of various wear mechanism is very helpful for the design of cutting tool material and 10 .CHAPTER . For the researcher and tool manufacturer tool wear progress and tool wear profile are also concerned.g. The cost and time for tool replacement and adjusting machine tool increases cost and decreases the productivity. Throughout the world today. Tool life equation gives no information about the wear mechanism. a large amount of research has been carried out in order to optimize cutting process in terms of improving quality. increasing productivity and lowering cost. Although Taylor’s equation gives the simple relationship between tool life and a certain cutting parameters. the prediction of tool wear is performed by calculating tool life according to experiment and empirical tool life equations such as Taylor’s equation or its extension versions. When tool wear reaches a certain value. there is a continuous struggle for cheaper production with better quality. Cutting tools may fail due to the plastic deformation. Machining operations comprise a substantial portion of the world’s manufacturing infrastructure. Hence tool wear relates to the economic of machining and prediction of tool wear is of great significance for the optimization of cutting process. machining quality. Because of its great economic and technical importance.
dimension and finish. cutting temperature. Among them. In addition. under conditions of very high stress at high temperature. and it will result in the failure of the cutting tool. such as Usui’s tool wear equation [15]. wears are occurring during the cutting action. cutting temperature of tool face and normal pressure on tool face. During cutting.1 TOOL WEAR Cutting tools are subjected to an extremely severe rubbing process. However. including those very difficult to detect by experimental method. numerical methods such as finite element method (FEM). cutting tools remove the material from the component to achieve the required shape. which 11 .1 TOOL WEAR PHENOMENA Under high temperature. finite difference method (FDM) and artificial Intelligence (AI) are widely used in machining industry. new equation must be established by making experiment. high pressure. They are in metaltometal contact. When the tool wear reach certain extent. etc can be predicted by performing chip formation and heat transfer analysis in metal cutting. between the chip and work piece. strain. high sliding velocity and mechanical or thermal shock in cutting area. For example. the tool or edge change has to be replaced to guarantee the ordinary cutting action. with the emergency of more and more powerful computer and the development of numerical technique. cutting tool has normally complex wear appearance.geometry. 1. Therefore a new tool wear prediction method may be developed by integrating FEM simulation of cutting process with tool wear model. FEM has become a powerful tool in the simulation of cutting process because various variables in the cutting process such as cutting force. Some tool wear equations related to one or several wear mechanisms are also developed.1. 1. when tool geometry is changed. and [19]. such tool life equations are valid under very limited cutting conditions. strain rate. The situation is further aggravated due to the existence of extreme stress and temperature gradients near the surface of the tool. In the recent decades. stress. Mostly researchers concentrate on the study of wear mechanism and investigate the mathematical relationship between wear due to various wear mechanisms and some cutting process variables such as relative sliding velocity of workpiece material along tool face.
1: Types of Tool Wear • Crater wear: In continuous cutting. Crater wear is improved by selecting suitable cutting parameters and using coated tool or ultrahard material tool. because the tool edge is weakened by the severe cratering and eventually fractures. for example in turning operation. insert breakage.1 are the most common wear types [28]. fatigue crack. crater wear normally forms on rake face. crater wear is often the factor that determines the life of the cutting tool. plastic deformation and buildup edge. brittle crack. Crater wear and flank wear shown in figure1. thermal crack. At high cutting speed. flank wear.consists of some basic wear types such as crater wear. Crater wear and flank wear shown in figure1.2: Behaviour of Flank wear 12 . The dominating basic wear types vary with the change of cutting conditions.1 are the most common wear types. It conforms to the shape of the chip underside and reaches the maximum depth at a distance away from the cutting edge where highest temperature occurs. Figure 1. Figure1.
showing the initial wear.Under mild wear conditions. oxidation wear. diffusion wear. adhesive wear.2 WEAR MECHANISM In order to find out suitable way to slow down the wear process. diffusion wear and oxidation wear are very important. This is a mechanical wear. 1. and it is the main cause of the tool wear at low cutting speed. Hence the width of the flank wear land “VB” is usually taken as a measure of the amount of wear and a threshold value of the width is defined as tool reshape criterion. and the formation of relatively large wear particles. abrasive wear.2 shows a variation of flank wear rate with cutting time. Figure1. etc.1. temperature and vibration. Due to the high pressure and temperature. It is responsible for a poor surface finish. a decrease in the dimension accuracy of the tool and an increase in cutting force. 13 . • Abrasive wear: Abrasive wear is mainly caused by the impurities within the workpiece material. Among them. • Adhesive wear: The simple mechanism of friction and wear proposed by Bowden and Tabor is based on the concept of the formation of welded junctions and subsequent destruction of these. adhesive wear. Severe wear is characterized by considerable welding and tearing of the softer rubbing surface at high wear rate. such built up edge (BUE). the surface finish of the sliding surfaces improves. Adhesion wear occurs mainly at low machining temperatures on tool rake face. It is found that tool wear is not formed by a unique tool wear mechanism but a combination of several tool wear mechanisms. welding occurs between the fresh surface of the chip and rake face because of the chip flowing on the rake face results in chemically clean surface. such as carbon. nitride and oxide compounds. steady wear. solution wear. delamination wear. many research works are carried out to analyze the wear mechanism in metal cutting. as well as the builtup fragments. Tool wear mechanisms in metal cutting include abrasive wear.• Flank wear: Flank wear is caused by the friction between the newly machined work piece surface and the tool flank face. electrochemical wear. and severe wear periods.
This flow may produce major changes in the tool geometry.• Diffusion wear: Wear is a process of atomic transfer at contacting asperities. for example Co3O4. WO3. A slight oxidation of tool face is helpful to reduce the tool wear. Intermittent cutting action leads to continual generation of heat and cooling as well as shocks of cutting edge engagement. (i) Gross softening of the tool: Diffusion of carbon in a relatively deep surface layer of the tool may cause softening and subsequent plastic flow of the tool. which result in high forces and a sudden complete failure of the tool. A number of workers have considered that the mechanism of tool wear must involve chemical action and diffusion. • • Chemical wear: Corrosive wear (due to chemical attack of a surface) Fatigue wear: Fatigue wear is often a thermomechanical combination. With HSS tools. There are several ways in which the wear may be dependent on the diffusion mechanism. TiO2. • Oxidation wear: High temperatures and the presence of air mean oxidation for most metals. and then taken away by the chip and the workpiece. which is oxidation wear. iron diffusion is possible. But at high temperature soft oxide layers. diffusion and current by isolating the tool and the workpiece. It reduces adhesion. (ii) Diffusion of major tool constituents into the work (Chemical element loss): The tool matrix or a major strengthening constituent may be dissolved into the work and chip surfaces as they pass the tool. They have demonstrated welding and preferred chemical attack of (W) tungsten carbide in (WTi) tungstentitanium carbides. this may be the prime wear phenomenon. this thin layer can be removed by fracture or chipping. This results in a rapid tool material loss. (iii) Diffusion of a workmaterial component into the tool: A constituent of the work material diffusing into the tool may alter the physical properties of a surface layer of the tool. the diffusion of lead into the tool may produce a thin brittle surface layer. For example. are formed rapidly. 14 . but it seems unlikely to be the predominant wear process. Temperature fluctuations and the loading and unloading of cutting forces can lead to cutting edge cracking and breaking. In cast alloy. Diamond tool – cutting iron and steel is the typical example of diffusion wear. carbide or ceramic tools.
diffusion wear and oxidation wear.3 PREDICTION OF TOOL WEAR Prediction of tool wear is complex because of the complexity of machining system [15]. 15 . Tool wear in cutting process is produced by the contact and relative sliding between the cutting tool and the work piece and between the cutting tool and the chip under the extreme conditions of cutting area. tool. hardness.1.Under different cutting conditions dominating wear mechanisms are different. interface and machine tool: • Workpiece: It includes the workpiece material and its physical properties (mechanical and thermal properties. the dominating wear mechanisms vary with cutting temperature. Figure 1. For a certain combination of cutting tool and workpiece. microstructure.3. which determine cutting force and energy for the applied cutting conditions. According to the temperature distribution on the tool face.3: Wear mechanisms 1. etc).79 N/mm2. it is assumed that crater wear is mainly caused by abrasive wear. but flank wear mainly dominated by abrasive wear due to hard second phase in the workpiece material. Any element changing contact conditions in cutting area affects tool wear. These elements come from the whole machining system comprising workpiece. temperature at the cutting edge can exceed 530°C and pressure is greater than 13.4 shows influencing elements of the tool wear [15]. Figure 1. as shown in figure1.
semiroughing. plays an important role for a successful cutting. such as the minimum liquid lubrication. coolants are used to decrease cutting temperatures and likely reduce tool wear. In 80% of the industrial cutting applications. tooling costs.Figure 1. depth of cut) • Interface: It involves the interface conditions. etc) need to be appropriately chosen for different operations (roughing. Increasingly new technologies. product quality. and 16 . The optimal performance of a cutting tool requires a right combination of the above tool parameters and cutting conditions (cutting speed. This is because tool change strategies. • Dynamic: The dynamic characteristic of the machine tool. rake angle. have been developed to reduce the cost of coolant that makes up to 16% of the total machining costs. tool coatings and tool geometric design (edge preparation. affected by the machine tool structure and all the components taking part in the cutting process.4: Influencing elements of tool wear • Tool: Tool material. Instable cutting processes with large vibrations (chatters) result in a fluctuating overload on the cutting tool and often lead to the premature failure of the cutting edge by tool chipping and excessive tool wear. or finishing). The problem of tool wear monitoring in machining operation has been active area of research. feed rate.
In addition. Taylor’s tool life equation reveals the exponential relationship between tool life and cutting speed. A and B are defined by doing a lot of experiments with cutting speed changing and fitting the experimental data with the equation. They can be categorized into two types: Tool life models and Tool wear rate models. It is very convenient to predict tool life by using this equation. They provide the information about wear growth rate due to some wear mechanisms.g.productivity are all influenced by tool wear. the wear growth rate. Reduction in production cost and increase in productivity can be realized by making the most use of a tool’s life and therefore increasing the time between tool changes. 17 .e. the rate of volume loss at the tool face (rake or flank) per unit contact area per unit time (mm/min). In various sizes of cutting database. Taylor’s tool life equation and its extension versions under different cutting conditions appear most frequently. The constants n. as shown in table 1. i.1. except that tool life can be predicted by these equations. As the new machining technologies. For example. tool wear profile or tool wear mechanisms that are sometimes important for tool designers. and Hastings tool life equation describes the great effect of cutting temperature on tool life [19]. Tool life equations are suitable to very limited range of cutting conditions.1. 1.4 TOOL WEAR MODELS Many mathematical models are developed to describe tool wear in quantity. e. the existing tool life equations need to be updated with new constants and a lot of experimental work has to be done. are getting spread in manufacturing industry. are related to several cutting process variables that have to be decided by experiment or using some methods. C1. Tool wearrate models: These models are derived from one or several wear mechanisms. highspeedcutting or dry cutting. In these modes. Tool life models: This type of wear models gives the relationship between tool life and cutting parameters or variables. and have been elaborated below. it is difficult to get further information about the tool wear progress.
p. Another part including universal gas constant and tool temperature describes diffusive wear.C2 = constants) (G. f ) + D exp dt RT ( n.q. E = process activation energy Vs = sliding velocity .BHN = Workpiece hardness. d = Depth of cut T = Cutting temperature . Usui’s equation includes three variables: Sliding velocity between the chip and the cutting tool. dW/dt = wear rate (volume loss per unit contact area per unit time) Takeyama & Murata’s model is developed by considering the combination action of abrasive wear and diffusive wear.B =constants) (A. f = Feed rate.D =constants) Taylor’s extended equation: V= C3 L f d ( BHN / 200) r m p q Usui’s wear model (considering adhesive wear): dW −B = Aσ nVs exp dt T ( m.Table 1.C3 = constants) Temperaturebased equation(known as Hasting’s tool life equation): TLB = A ( A.q. Therefore Usui’s equation is very practical for the implementation of tool wear estimation by using FEM or by using the combination of FDM and analytical method.B = Constants) V = Cutting speed .L = Tool life .1: Tool life and Tool wear rate models Empirical Tool Life Models Taylor’s basic equation: VL = C1 n Tool Wear Rate Models Takeyama & Murata’s wear model (considering abrasive wear and diffusive wear): dW −E = G (v. σ n = Normal Stress.r.R = universal gas constant . These variables can be predicted by FEM simulation of cutting process or combining analytical method and FDM.C1 = Constants ) Taylor’s extended equation: L= C2 V f qd r p ( p. Therefore the equation sums two parts up.r. tool temperature and normal pressure on tool face. 18 . One part shows that abrasive wear is influenced by the cutting speed and feed.
Influence on cutting forces: Flank wear (or wearland formation) and chipping of the cutting edge affect the performance of the cutting tool in various ways. Clearanceface (flank or wearland) wear and chipping almost invariably increase the cutting forces due to increased rubbing forces.2. Increase the cost. Dimension accuracy: Flank wear influences the plan geometry of a tool this may affect the dimensions of the component produced in a machine with set cutting tool position or it may influence the shape of the components produced in an operation utilizing a form tool. reduce forces by effectively increasing the rake angle of the tool.1 CONSEQUENCES OF TOOL WEAR • • • • • • • Decrease the dimension accuracy. Vibration or chatter: The vibration is another aspect of the cutting process which may be influenced by flank wear. The cutting forces are normally increased by wear of the tool. This is particularly true of a tool worn by chipping and generally the case for a tool with flankland wear – although there are circumstances in which a wear land may burnish (polish) the workpiece and produces a good finish. 1. under certain circumstances. Increase the cutting force. Surface finish (roughness): The surface finish produced in a machining operation usually deteriorates as the tool wears. A wear land increases the tendency of a tool to dynamic 19 . however.2 EFFECTS OF TOOL WEAR ON TECHNOLOGICAL PERFORMANCE 1. Increase the temperature. Lower the production efficiency. Increase the surface roughness. Crater wear may. component quality.The constants in tool wear rate models are depending on the combination of workpiece and cutting tool material. Likely cause vibration.
1. It can increases tool wear and thereby reducing tool life [17]. 1. Some of this heat conducts into cutting tool. It is commonly accepted that both the wear and failure mechanisms which develop in cutting tools are predominantly influenced by temperature and it also results in modification to the properties of workpiece and tool material such as hardness. Figure 1.instability. and in many cases constituents of the tool life may diffuse into the chip or react chemically with the workpiece or cutting fluid. generalized wear theory cannot be directly used for accurate study of the tool wear.3 THERMAL ANALYSIS: In machining operations. mechanical work is converted to heat through the plastic deformation involved in chip formation and through friction between the tool and workpiece. Tools become softer and wear more rapidly by abrasion as temperatures are increased. In order to predict the wear and failure characteristics of a tool. it is necessary to quantify the temperatures which develop during the cutting operation. machined part’s dimensional accuracy. A cutting operation which is quite free of vibration when the tool is sharp may be subjected to an unacceptable chatter mode when the tool wears.2.2 CHARACTERISTICS OF TOOL WEAR • • Huge contact stress at the rake and flank surface High temperature (8001000 °C for carbide and steel combination) Hence. resulting in high tool temperatures near cutting edge. as well as in the tool life in machining.5 shows three regions of heat generation in turning. which are. In machining operations. the shear zone.1 HEAT GENERATION IN MACHINING Heat generation while machining has significant influence on machining. Elevated tool temperatures have negative impact on a tool life. 1. mechanical work is converted to heat through the plastic deformation involved in chip formation and through friction between the tool and workpiece. The temperature of the tool plays an important role in the thermal distortion and the.3. the chiptool interface and the toolworkpiece interface zone [17]: 20 . It gives rise to thermal softening of cutting tool.
This causes a further rise in the temperature of the chip. Figure 1. The main techniques used to evaluate the temperature during machining are as following: 21 . the chip thickness decreases and less shear energy is required for chip deformation so the chip is heated less from this deformation. where secondary plastic deformation due to friction between the heated chip and tool takes place. at flanks where frictional rubbing occurs. Part of this heat is carried away by the chip when it moves upward along the tool. It is increasingly important to understand how machining temperature are affected by the process variable involved which are cutting speed. 1. This chiptool interface contributes 1520% of heat generated. As the portion of heat that flows into the tool cause very high temperature in vicinity of tool tip which in turn decrease the hardness of the tool material and in extreme case may even cause melting. resulting in a decrease in useful life of the tool. as the cutting speed increases for a given rate of feed. About 8085% of the heat generated in shear zone. This area contributes 13% of heat generated.• The shear zone: The shear zone. This heat raises the temperature of the chip.3.2 ANALYSIS TECHNIQUES Several methods have been used for measuring the temperatures generated during metal cutting operations [12]. and tool geometry. Considering a continuous type chip. The wear rate of tool therefore increases. • The toolworkpiece interface zone: The worktool interface zone 3. feed rate. • The chiptool interface zone: The chiptool interface zone. where the main plastic deformation takes place due to shear energy.5: Zones of heat generation & dissipation during the metal cutting process.
and air present at ambient temperature [8].3 HEAT TRANSFER IN MACHINING Heat is transferred across boundaries by conduction. these are: • • • • • • ToolChip Thermocouple Technique Embedded Thermocouple Technique Infrared Radiation Technique Metal Microstructure and Microhardness Variation Measurement Thermosensitive Painting Technique Temper Color Technique Numerical Simulation: The numerical methods were successfully applied in calculating the temperature distribution and thermal deformation in tool. the tool and toolholder is by conduction. • • • Heat transfer inside the chip and workpiece. they have great potential to solve the problems in practice. convection and radiation because of the temperature gradient. Heat transfer between coolant/air and the chip/tool/workpiece is by convection. some information such as chip surface temperature or temperature distribution in workpiece is first obtained experimentally. 22 . chip and workpiece. The inverse heat transfer problem in machining is an example of these methods. These numerical methods used in measurement of temperatures are the following: • • • Finite Difference Method Finite Element Method Boundary Element Method SemiAnalysis: In the semi analysis technique. Radiation is rarely investigated in traditional machining operations.3. 1. Then the temperature distribution and/or thermal deformation in chip and sometimes in the tool and workpiece as well are calculated analytically. Especially. the finite element and boundary element methods can deal with very complicated geometry in machining. chip or workpiece temperature and their distribution.Experiment Retrospection: Many experimental methods have been devised to measure the tool.
severe deformations take place in the vicinity of the cutting edge of the tool because of the high temperatures resulting from machining operation. The Present work is also based on the application of finite element for thermal analysis of single point cutting tool for turning operation. it can also be implemented for other multipoint processes like drilling. a complex region defining a continuum is discredited into simple geometric shapes called finite elements. fluid flow. Applications range from deformation and stress analysis to field analysis of heat flux.1. 23 . These elevated temperatures have a negative impact on tool life. magnetic flux. Once the model developed for determination of temperature field for single point cutting tool. • • • • Heat Effects on Tool Life Heat Influences on Surface Toughness Heat Influences on Thermal Deformation in Lathe. and quality of surface. milling or grinding also. Heat Effects on Mass Transfer in Coolant Circulation System.5 Finite Element Method in Thermal Analysis Finite element analysis is a most useful and accurate approach for the determination of field variables that is made possible by advancements in computational and processing power of computers and thus it is almost used for all the computer aided design methodologies in recent years. 1. seepage and other flow problem. In this method of analysis. Following are some of the effects of heat on various cutting parameters: • Heat Influences on Cutting Forces: The heat influence on the cutting forces is mainly because of the following reasonsthe friction coefficient is tightly dependent upon temperature. and the properties of cut material also depend on temperature.3.4 HEAT EFFECTS In metal cutting.3.
CHAPTER  2 LITERATURE REVIEW
The problem of tool wear monitoring in machining operations has been an active area of research for quite some time. The machining processes are inherently dynamic in nature due to various factors. Some of them can be mathematically modeled, but others are too uncertain. Thus simplifications are made while modeling the extremely complex machining processes. Research in the field of machining has been primarily done on single point turning process, as it is the basic metal removal processes. Once a model has been developed for turning operation, it can be implemented for other multipoint processes like drilling, milling or grinding. In this work tool wear along with temperature had been selected as the criterion for the process control in turning operation. In recent years, numerical calculating methods have been widely developed in most areas of engineering and have been used to determine the thermal behaviour of cutting tools. In general, the application of finite element and finite difference techniques has been successful, yet still relies heavily on the accuracy of experimentally determined boundary conditions. This chapter deals with the review of the work done on the topic. Firstly the review is on the general analysis of tool, concentrating mainly on prediction of temperature and tool wear. Then the concentration shifts on to second part, which is the review on use of finite element in the thermal analysis of the cutting tool.
2.1 MODELS FOR DETERMINATION OF TEMPERATURE FIELD
Temperature measurement and prediction have been a major focus of machining research for several decades. Throughout the 20th century, much effort has been undertaken into measuring the temperature generated during cutting operations. Interfacial temperatures in machining play a major role in tool wear and can also result in modification to the mechanical properties of the workpiece and cutting tool. Leshock et al [4] presented the results the tool chip interface temperature measurement by the tool work thermocouple technique. Tool chip interface temperature is analyzed under a wide range of cutting condition during turning of 4140 steel alloys and Inconel 718 nickel based alloys with tungsten carbide tools. The obtained experimental results are compared with the predictions based on the Loewen and Shaw’s 24
model. In addition an empirical model for the tool face temperature terms of cutting parameters is established. Finally, the tool chip interface temperature is analyzed with both flank and crater wear during machining of 4140 steel alloys. Sullivan et al [12] presented different methods used for the measurement of temperature of a single cutting tool. Initial experiments conducted involved the simultaneous measurement of forces & temperature. Use of the toolchip interface as a thermocouple was one of the first methods of estimating interfacial temperatures in machining process. These experiments focused on the use of embedded thermocouples and using the infrared camera to monitor the process. Komanduri et al [13] addresses two fundamental thermal issues of tribology in orthogonal machining with a sharp tool, namely, the nature of the apparent heat partition in the shear plane and the variable heat partition at the chiptool interface. The distribution of temperature in the chip, the tool, and the work material was determined analytically considering the combined effect of these two heat sources in orthogonal machining. The new analytical model was verified for a wide range of Peclet numbers, using the available experimental data from the literature. Huda et al [14] developed a technique for measuring temperature at the interface between a cutting tool and a chip. A twocolor pyrometer with fused fiber coupler was applied to the temperature measurement of the toolchip interface in dry and wet turning. By using this pyrometer, it is possible to measure the temperature of a very small object without emissivity affecting the results. The temperature distributions on the cutting tool and the work material were analyzed using the finite element method. Good agreement was obtained between the analytical results and experimental ones. Miller et al [21] developed Experimental techniques using modern, digital infrared imaging and successfully applied them during this study to gather cutting tool temperature distributions from orthogonal machining operations. This new process has seemingly overcome many problems associated with past experimental techniques. Ranc et al [23] developed a highspeed broad band visible pyrometer using an intensified CCD camera (spectral range: 0.4 mm–0.9 mm) for the measurement of the machining temperature. The maximum temperature in the chip can reach 730°C and minimal temperature which can be detected is around 550°C. The advantage of the 25
visible pyrometry technique is to limit the temperature error due to the uncertainties on the emissivity value and to have a good spatial resolution (3.6 mm) and a large observation area.
2.2 APPLICATION OF FEM FOR TOOL WEAR RESEARCH
A more promising approach for developing an orthogonal metal cutting model is provided by an advanced numerical discretization scheme, such as the finite element method. This part basically discusses about the application of FEM in predicting the tool temperature and thus estimating the tool wear. Shih et al [1] developed the, methodology using FEM for the simulation of plane– strain orthogonal cutting processes with continuous chip formation. The orthogonal metal cutting experiment was setup on a shaper, and the distributions of the residual stresses of the annealed carbon steel are measured using the Xray diffraction method. Along with this, they also developed experimental procedures for orthogonal metal cutting and measurement of distributions of residual stresses using the Xray diffraction method. They formulated a 4 nodes 8 degree of freedom, quadrilateral plane–strain finite element. The finite element formulation was divided in two phases. Only thermal finite element formulation is discussed here. •
Thermal finite element formulation: The temperature increment during the metal
cutting process is simulated using a linear thermal finite element formulation by assuming that the thermal conductivity, density and heat capacity of the workpiece material remain unchanged during the displacement increment. The thermal finite element formulation for temperature analysis can be written in a matrix form as
. . . [C ] T + ([ K k ] + [ K c ]){T } = Fp + Ft Where, [C] = ∫ {N }{N }T ρcdV
v
(2.1)
[Kk]= ∫ [ B] [ B]kdV
v
T
[Kc]= ∫ {N }T {N }hdS c
Sc
26
= Temperature vector at nodal points = Shape function vector = Heat capacity of workpiece = Convection coefficient = Convection boundary of the workpiece { F p } = Vector of heat generation due to plastic work . = Rate of plastic work t { F } = Heat generation rate on the boundary node of the workpiece due to frictional work ρ . They developed a package for estimating the thermal behavior of both single and multipoint cutting tools using base data which are generally available. lowcost package would be useful for giving an indication of the expected thermal behavior of surface engineered cutting tools. The temperature distribution along the tool/chip interface is applied as a heat source input to a finite element model of the tool.1). The finite element predictions of the residual stresses were compared with measurements obtained from Xray diffraction. the temperature distribution of the workpiece is obtained and the material properties are thus generated. or may be acquired through standard cutting tests. and h are all assumed as direction independent. this easytoapply. was used to simulate the material deformation during cutting process. q . Detailed workmaterial modeling. c. 27 .{ F p }= ∫ {N }qdV & v . {T} {N} c h Sc . which included the coupling of large strain. Shih [2] developed plane – strain Finite Element Method and applied to analyze the orthogonal metal cutting process. and the product testing involved. Here. rapid. k . Based on the equation (2. They concluded that with the continued development of surface engineered cutting tools. They concluded that finer element mesh configuration should be used to achieve more accurate modeling of the cutting process and also to improve the FE predictions. Gillibrand et al [3] developed a technique to predict the temperatures generated along the tool/chip interface using standard analytical methods. high strain rate and temperature effects.
Tool nose radius was also varied.Mills et al [5] developed a technique to monitor the deformation and crack propagation around inclusions using a micro cutting device in a scanning electron microscope while machining is being carried out. The temperature distributions determined from this procedure were compared with those obtained experimentally. Tieu et al [6] presented a research work carried out on the cutting tool temperature field with adhering layer formation when machining CaS treecutting stainless steel. tool wear is strongly influenced by the cutting temperature. The correlations for workpiece temperature of cutting speed & feed have been developed. The method involved as interactive procedure to determine temperature distributions in the tool from varying heat flux transfer conditions. These process variables depend on tool and workpiece materials.25 to 0. The cutting temperatures of a 0. and relative sliding velocity at the interface.5 mm from the major cutting edge is much smaller in the presence of an adherent layer than without an adherent layer. It was found that the temperature gradient in the cutting tool from the tool face at a position 0.16 % carbon bright drawn mild steel. It showed that cutting speed & feed rates have significant impact on temperature but nose radius has little effect. Yen et al [15] developed a methodology to estimate the tool wear of carbide tool in orthogonal cutting using FEM. Chu et al [7] developed technique for measuring temperature close to primary cutting edge in turning operation. cutting condition. contact stresses. By means of combining thermocouple measuring method and finite element (FE) analysis. Based on the experimental work using a miniature thermocouple and the analytical results from FE modeling. tool 28 . In metal cutting. A coincidence of the experimental and theoretical temperature distributions implied that the chosen heat flux model was appropriate. Ostafiev et al [8] analyzed heat flux transfer in the cutting tool in steady state orthogonal cutting. The temperature distribution field within a cutting tool under conditions of adherent layer formation was determined using the FEM. the cutting temperature distributions and their relation with the formation of adhering layer were investigated. they concluded that the adhering layer thickness was uneven and the average temperature of cutting zone for adhering layer formation was within a range of 9501050°C. have been measured for a range of cutting speed and feedrates at a constant depth of cut.
the second phase includes. a development of tool wear model for the specified toolworkpiece pair. Zhao et al [18] developed a methodology to investigate the effects of the internal cooling on the flank wear of the cutting tools in orthogonal cutting. In order to obtain the cut chip geometry near the steady state. use of coolants etc. developed by WZL at University of Aachen (RWTH). w the width of cut and θ is the relief angle of the tool[18]. for the given application. as shown 29 . “KontiCut”. Mathematically wear can be expressed as follows: dW = K σ t dL H The wear volume can be converted to the wear land measurement VB with the assumption of a zero degree rake angle of the cutting tool W= 1 wV B2 tan θ 2 Where. A flank wear model for a cutting tool in orthogonal cutting is presented which is based on previous wear models and includes the normal stress and the effect of temperature on the flank wear.geometry. a special simulation module. hardness H and normal stress σ t are two main parameters closely related to the wear and the wear rate is usually proportional to σ t and inversely proportional to H. the wear performance of carbide cutting tools and HSS cutting tools are different due to their different thermal softening behavior. Germany. The wear prediction procedure starts with a coupled thermoviscoplastic Lagrangian cutting simulation with isotropic strainhardening using DEFORM®2D. VB is the measurement of wear land on the tool. tool wear may be estimated with acceptable accuracy by using an empirical wear model and using FEM simulation. the first phase includes. Flank wear model for orthogonal metal cutting In all the previous wear models studied by them. Based on temperatures and stresses on the tool face. W is the volume worn away on the relief face. was utilized. According to the prediction of this model. and they have formulated the following methodologies: 1. The methodology proposed by them has three different phases. modifications in the commercial FEM code and last phase includes experimental validation of the developed methodology.
and t is the cutting time. L is the cutting length. Effects of temperature on flank wear in orthogonal cutting To consider the effects of the temperature on the flank wear. Ho and α are constants obtained by Curvefitting . H is the hardness of the cutting tool. VB the flank wear and θ is the relief angle 2. it is necessary to know the thermal softening of the cutting tool material versus the temperature. The apparent area of the tool–work contact interface can be written as follows: A = w VB The normal stress at the flank face can be calculated as given by the following relation: σt = Where Ft is Ft F = t A wV B the thrust force in cutting .VB is a variable that increases with the development of flank wear. T is in ◦C.1. Figure 2.1: Schematic of cutting tool with zero degree rake angle. where w is the tool width. VC is the cutting speed. K is a coefficient which can be determined by experiments.in figure 2. Thus the equation to predict flank wear can be written as: 1 1 2V 3 F t 3 VB = K 2 c t w tan θ H Where. The exponential function used to predict thermal softening is as follows: H (T) = Ho exp (−αT) Where H (T) is the hardness of a material at a given temperature.Since the relationship between the thermal 30 .
2122. YC Yen et al [19] developed a methodology to estimate the tool wear and tool life of a carbide tool in orthogonal cutting using FEM simulation. C3 and C4 are constants that can be determined by curvefitting.5853. The flank wear in arbitrary units versus the temperature was calculated by them for both carbide and HSS material. For HSS Tool Material C1 = −0. C3 and C4 for different tool materials are: For Carbide Tool Material C1 = 0. The proposed procedure for predicting the tool wear at any time instance tk was divided in four phases. C2. The values of C1.000006. C3 = 0.0054. C3 = −0. Amir et al [20] developed methodology to extend the applicability of Oxley’s analysis of machining to a broader class of materials beyond the carbon steels used by Oxley and coworkers. and C4 = 853. T is the temperature in ◦C and C1. The following is the equation used them: H (T) = C1T 3 + C 2T 2 + C 3T + C 4 Where H is the hardness of the cutting tool material.000002. and C4 = 1517. different equations can be used. Arsecularatne et al [22] investigated the application of the Oxley modeling approach to high speed machining (HSM) process for gaining a fundamental 31 . C2 = −0.81. • • • • “Konti Cut” Simulation Pure Heat Transfer Analysis Calculating Tool Wear Rate Updating the Tool Geometry The simulations using a cutting tool with constantly updated rake face and flank face geometries have shown that it is possible to predict the evolution of tool wear at any given cutting time from FEM simulations by using the proposed methodology by them. The performance of the model was studied by comparing its predictions with experimental data for different materials and it was found that model accurately produces the dependence of the cutting forces and chip thickness as a function of undeformed chip thickness and cutting speed and accurately estimates the temperature in the primary and secondary shear zones.softening and temperature can be obtained by curvefitting experimental data. C2.0002. C2 = 0.
it can be concluded that FEM has been effectively implemented to determine the temperature distribution on the tool surface. 2. efficient use of machine tools and. the surface contact between chip and tool and the temperature distribution at the rake face which affects strongly the tool wear. The material characteristics such as strain rate sensitivity. Since machining parameters affect the wear and heat generation in tool. the contact length between the chip and the tool and the temperature distribution at the tool–chip interface which has an important effect on tool wear. In the present work. Moufki et al [26] developed an analytical approach for thermomechanical modeling of oblique cutting process. The model presented can be used to predict the cutting forces. Molinari et al [27] developed an analytical approach to model the thermomechanical process of chip formation in a turning operation. this theory has been applied for two plain carbon steels and low alloy steel under HSM conditions. the global chip flow direction. Good agreement has been shown between measured and predicted results. A critical study was also presented by them in order to show the influences of the input parameters of the model including the normal shear angle. so further study has been carried out to develop the relation between machining parameters and mechanical properties which are governed by modified machining temperatures due to strain rate. 32 . strain hardening and thermal softening were considered. chip thicknesses.3 SUMMARY OF LITERATURE From above literature review. The predicted cutting forces. in order to predict the tool wear. The model permits to predict the cutting forces.understanding and performance prediction of this process which is gaining increased popularity due to its many economic and technological advantages such as faster metal removal rates. the thickness of the primary shear zone and the pressure distribution at the tool–chip interface. the chip flow direction. The tendencies predicted by the model were also compared qualitatively with the experimental trends founded in the literature. and secondary deformation zone thicknesses are then compared with the experimental results obtained under identical conditions. improved surface finish and lower cutting forces.
caused by that force. Out of these. Here hardness is related with the modified temperature. In this category. 3. 5. Piezoelectric crystals. The dial indicator. Strain Gauges.CHPATER .1 FORCE MEASUREMENT A force measurement actually involves the measurement of a deflection.1 INSTRUMENTATION The various instruments used for experimentation are discussed here in this section: 3. 2. bounded. ∈ is the normal strain and can be calculated as: ∈= 33 . Optical devices. feed rate (f). most widely used dynamometer is of strain gauge type. Some of them are listed below: 1. with a suitable calibration between the force and the deflection it produces.3 INSTRUMENTATION AND EXPERIMENTATION The objective of the present work is to develop methodology to relate tool wear with mechanical properties of a material such as Hardness. various devices have been used. 3. Pneumatic devices. Usually these bonded wire gauges have been specified by the resistance and the gauge factor (F).wire strain gauges have commonly been used. 4. For measuring small deflections.1. The gauge factor is a measure of sensitivity of gauge and is defined as: F= ∆R R ∆R = ∈R ∆l l ∆l l Where. Finite Element Analysis is used to depict the temperature at various points of cutting tool by changing various machining parameters such as cutting speed (V). of cutting tool. including the effect of strain rate. depth of cut (d).
Fc. Ff.1[24]. the changes of the resistance of the same order of magnitude need to be measured.1: Wheatstone bridge Figure 3. Figure 3. the lathe operation is frequently taken as a orthogonal cutting process. and the tangential cutting force.2: Dynamometer 34 . bonded wire strain gauge of resistance 120+ and gauge factor 2. have been used. have been used. In order to measure the strains of the order of 1+. No current will flow through the galvanometer (G) if the four resistances satisfy the equation R1 R2 = R4 R3 For the sake of simplicity. the axial cutting force. the resultant force will act in a known plane and only two force components are required to analyze the cutting process.In our case. In this case. In the present case. This can be made by means of Wheatstone bridge as shown in figure 3. A schematic diagram of the dynamometer used in the present work is shown in the figure 3.2[24].
Ff. EN 24 steel workpiece of 600mm length was held in a three – jaw chuck and supported by a center in the tail stock. The straight edge with Rake angle α = 0 has been used to have an orthogonal cutting. A total of eight experiments were carried out. bends the structure about another axis. The action of the forces is to bend the structure. The output flank wear was measured with the help of a tool room microscope. Tool height and tool overhang was set to the required level with the help of gauges. all with the same basic 35 .2 EXPERIMENTAL PROCEDURE The experiments were made on the HMT lathe using a bar turning process under dry conditions.2.2. and the recordings are calibrated to give a measure of the forces applied. To reduce the total number of experiments.A two component cutting force dynamometer of cantilever type is used in the present work. Strain gauges have been used to measure these distortions (moments).1 PLANNING OF EXPERIMENT A scientific approach to planning of experiments must be incorporated in order to perform an experiment most effectively. For the experimentation. bends the structure about the one axis and the tangential feed force. and depth of cut) it was required to measure the two force components Ft and Ff. A carbide tip turning tool was clamped in a two component strain gauge dynamometer using a tool holder designed in a machine lab during the thesis work. thickness of chip and flank wear. The dynamometer structure is made of aluminum. 3. Fc.2 EXPERIMENTATION Experiments were carried out on a turning lathe. 3. feed. Planning of experiments was employed in order to fulfill the following requirements: • • • To get the data uniformity distributed over the whole range of controllable factors to be investigated. To establish a relationship between different input variables and the output accurately in the selected range of investigation 3. A rough turning pass was made initially to eliminate the runout of the workpiece. Statistical design of experiments is the process of planning the experiments so that the appropriate data could be collected which may be analyzed by statistical method resulting in valid and objective conclusions. The axial cutting force. For the range of range of cutting conditions (cutting speed.
508. • Tool material: The tool material used should be capable of high speed machining with dry cutting conditions.configuration and carbide inserts were replaced after performing a single test so as to see the effect of temperature on the tool individually at different cutting conditions.82 (m/min) b) Feed: 0.35.175 (m/sec) c) Depth of cut: 0. In present investigation carbide inserts were used for performing the experiments.3: Dimensions of the workpiece The figure 3.27 (mm) 3.02mm b) Tool width: 8. 56 mm 600mm Figure 3. 36 .3 . 1. Figure3.1. The selected ranges of each parameter used are given below: • Work material: The EN 24 Steel (0.08 – 179.45.1.2.762.0.0787 – 0.8 %Ni) was chosen for the present investigation with a diameter of 60 mm and 600 mm length.4 shows the schematic diagram of the machine and equipment setup.6 %Mn.0. • Tool geometries: a) Tool length: 16.3 shows the dimensions of the workpiece (EN24) before the turning process.3 EXPERIMENT METHODOLOGY A HMT make lathe was used for turning experiment whose specifications have been given in appendix A.45 %C. 0.0.02 mm c) Nose radius: 0.4 mm • Test conditions: carbide inserts were used to machine EN24 steel with following cutting parameters a) Rotational speed:70.
Measuring the flank wear of the carbide insert with microscope. The output flank wear is measured with the help of a metallurgical microscope having graduation marked on the eyepiece.Workpiece Cutting tool Dynamometer Display Figure 3. depth of cut. Correlating these wear trend with thermal softening of tool due to rise in temperature in insert. 2. 37 . Machining is done with different sets of Cutting speed. Carry out experiment on lathe machine using EN 24 as work piece and commercial available Carbide Tool of triangular shape. Measuring the deformed chip thickness using vernier calliper. & feed rates.4: Schematic diagram of the lathe and equipment setup Then the actual experiments have been carried out with the different input cutting conditions for different experiments for constant volume of material removal in each case. 4. The experiments carried out can be classified: 1. 6. These input cutting conditions are fed to program and value of temperature and Hardness at every nodes of the tool is thus calculated. 5. 3. Measuring the cutting forces with dynamometer.
4. γ = . Internal heat generation is zero. and heat transfer is considered in threedimensional solid bounded by a surface Γ . 2. [20]. 4. and have been calculated by relation given below: . The eight noded brick elements have been used for the FEM modeling. Material is isotropic and homogeneous as (Kx = Ky = Kz = K) 3.1 GOVERNING EQUATION FOR THE HEAT TRANSFER Governing equation for the heat transfer problem can be written as: ∂ ∂T ∂ ∂T ∂ ∂T + K K + K +Q = 0 ∂x ∂x ∂y ∂y ∂z ∂z (4. γo o Here. [4].and [22].1) Following assumptions have been considered for the simplicity if the computation required: 1. γ T mod ( K) = Tavg 1 − ν log .2 BOUNDARY CONDITION Following boundary conditions have been used for the solution of the present problem: 1.4 ANALYSIS The present chapter deals with the formulation of threedimensional governing equation for heat conduction used to obtain the temperature distribution on the face of the tool bit. V ∆y r cos α φ = tan −1 1 − r sin α Figure 4. to be used for obtaining the hardness at the various positions on the tool. Conduction occurs in the steady state. This equation is solved with appropriate boundary conditions. machining 38 .CHAPTER . Temperature is specified at nodes which are in touch with shear zone[1].1: Model of chip formation used in Oxley’s analysis for Orth. cos α cos (φ − α ) .
3 FEM FORMULATION Using Galerkin’s orthogonality.dz − ∫ K ∂y i Ω Γ ∂T ∂T ∂N i dx.dz − ∫ K ∂x i i y.dz ∂x Ω ∫ ∂x K ∂x N dΩ = ∫ N K ∂x dy. z ∫ N K ∂y dx.dy − ∫ K ∂z i i x.2) can be obtained from the relations as written below: ∂ ∂T ∂T ∂T ∂N i dx.4 2.int erface (ο C) = 1700V 0.dz ∂z Ω ∫ ∂z K ∂z N dΩ = ∫ N K ∂z dx.dy. taking Where. z Ω 39 .2) Where dΩ = dx.2 f 0.dy. ∂ ∂T ∂ ∂T ∂ ∂T ∫ ∂x K ∂x + ∂y K ∂y + ∂z K ∂z N idΩ + Ω QNi dΩ = 0 ∫ Ω (4. Ω ∫ QN dΩ = 0 i The various components of equation (4.5d 0.1) becomes.dy. T ∞ = 27 ο C q n = h(T − T∞ ) hair =14 W/m2 oC q n = Heat flux normal to the boundary T∞ = Ambient temperature 4.dz ∂y = ∫ Ni K ∂ ∂T ∂T ∂T ∂N i dΓ − ∫ K dΩ ∂y ∂y ∂y Ω ∂T ∂T ∂N i dx. Thus.∆y = spacing between successive planes (25 *104 mm) Tavg.dy. since internal heat generation has been assumed to be zero. Convection is taking place on surface from the tool bit to air. equation (4. z Ω = ∫ Ni K Γ ∂T ∂T ∂N i dΓ − ∫ K dΩ ∂x ∂x ∂x Ω ∂ ∂T ∫ ∂y K ∂y Ni dΩ = Ω x.dz Now.
y and z direction respectively and can be written as: qx = −K ∂T ∂T ∂T .4) Where. qz in equation (4. and heat loss because of convection at the other surfaces of the tool exposed to air/coolant. qy. nx. q y = −K and q z = − K ∂x ∂y ∂z Putting these values of qx. ny. qy.2) becomes. nz are the direction cosines of unit normal to the surfaces.6) From equations (4. the equation (4. we have: ∂T ∂Ni ∂T ∂N i ∂T ∂N i − ∫ N i (qx nx + q y ny + qz nz )dΓ − ∫ K ∂x ∂x + ∂y ∂y + ∂z ∂z dΩ = 0 Γ Ω (4.3). let qn = q x nx + q y n y + q z nz Therefore equation (4.3) Let qx.6). ∫N K i Γ ∂T ∂N i ∂T ∂N i ∂T ∂N i ∂T ∂T ∂T dΓ + ∫ N i K dΓ + ∫ N i K dΓ − ∫ K ∂x ∂x + ∂y ∂y + ∂z ∂z dΩ = 0 ∂x ∂y ∂z Γ Γ Ω (4.5) and equation (4. Now the heat flux in the tool is because of the heat load at the specified contact of tool and workpiece. − ∫ N i q n dΓ − Ω ∂T ∂N i ∂T ∂N i ∂T ∂N i K ∫ ∂x ∂x + ∂y ∂y + ∂z ∂z dΩ = 0 Ω (4.= ∫ Ni K Γ ∂T ∂T ∂N i dΓ − ∫ K dΩ ∂z ∂z ∂z Ω Thus. which is specified by boundary conditions. as written below: 40 . qn is normal heat along the unit outward normal.5) Here.4) becomes. And. and qz be the heat flux in x. Thus. ∫ N i (qn )dΓ = ∫ qo N i dΓ + ∫ N i (h(T − T∞ ))dΓ (4. the final FEM equation has been developed.
7) is as given below: 1. are shape functions Γ Represents surface area A Further. dA=det J dξdη η Where N1 = (1 − η − ξ + ηξ ) 4 N 2 = (1 − η + ξ + ηξ ) 4 N 3 = (1 + η + ξ − ηξ ) 4 N 4 = (1 + η − ξ − ηξ ) 4 (1.1) 41 .7) is represented {Rq }.which represents heat load vector arising from specified surface heating {R q }= − ∫ q o [N ]T dΓ Γ N1 N 2 [N] T = N3 N 4 Where. N2. N1. N4. 1) (1. vector {Rq} can also be written as +1 +1 {R } q = −1 −1 ∫ ∫q o [ N ]T dA Here. 1) ξ (1. N3. The first part of equation (4.1) (1. Ni =. ∂T ∂x ∂N ∂N i ∂N i ∂T − ∫ q o N i dΓ − ∫ N i h (T − T∞ )dΓ − ∫ K i dΩ = 0 ∂ x ∂y ∂z ∂y Γ Γ ∂T ∂z 1 2 3 (4.7) Explanation of each part of above equation (4.
.. T = unknown surface temperature... + y8 ∂η ∂η ∂N ∂N 1 y1 + ... + 8 z8 ∂ξ ∂ξ ∂N 8 ∂N1 z1 + ...Jocobian matrix also represented as [J].. h = convective heat transfer coefficient T∞ = convective exchange temperature of air/fluid.. + ∂N 8 x8 ∂η ∂η ∂N ∂N 1 x1 + .. The first part of above equation is heat load vector arising from surface convention and denoted as {Rh } {Rh } = ∫ N i Γ h T∞ dΓ (4. + ∂ξ x8 [J ] = ∂N1 x1 + ... + 8 z8 ∂ζ ∂ζ Finally {Rq} equation written as below...9) Now vector {Rh} can further be written as: {Rh } = ∫ ∫ [N ] −1 −1 1 1 T h T∞ J dξ dη 42 .7) can be further expressed in two separate parts as − N i h(T − T∞ )dΓ = − N i hTdΓ + N i hT∞ dΓ written below: ∫ Γ ∫ Γ ∫ Γ Where. + 8 y8 ∂ζ ∂ζ ∂N ∂N1 z1 + . + 8 y8 ∂ξ ∂ξ ∂N 8 ∂N 1 y1 + . Second part of the equation (4. {R } = ∫ ∫ q [N ] q o −1 −1 1 1 T [ J ] dξ dη (4. which can be expanded as given below ∂N 8 ∂N 1 ∂ξ x1 + ... + 8 x8 ∂ζ ∂ζ ∂N ∂N 1 y1 + . + z8 ∂η ∂η ∂N ∂N1 z1 + ..8) 2..
10) 3.. {T} = Element Nodal Temperature Vector. It is represented by [K c ] {T } ∂T ∂x Where..... + T8 ∂y ∂y ∂y ∂y ∂y (4.11c) 43 ...11) Temperature gradient within the element is given by ∂N 3 ∂N 8 ∂N 2 ∂T ∂N 1 = T1 + T2 + T3 . T= Or......11a) (4.... + T8 ∂z ∂z ∂z ∂z ∂z (4... Where. K h = [ ] ∫ ∫ h[N ]T [N ] −1 −1 1 1 J dξ dη (4.. Thus we have...7) is the element conductance matrix related to the conduction (coefficient matrix). [Kh] = Element Conductance Matrix related to Convection..... ∑N T i =0 8 i i T = N1T1+N2T2+………………+ N8T8 Putting this in above equation..... The third part of equation (4..............Second part represents element conduction matrix related to convention and represented as: [k h ]{T } = − ∫ N i Γ h T dΓ Here.11b) ∂N 3 ∂N 8 ∂N 2 ∂T ∂N 1 = T1 + T2 + T3 . [K c ]{T } = K ∂N i ∂N i ∂N i ∂T dΩ ∫ ∂x ∂y ∂z ∂y Ω ∂T ∂z (4...... + T8 ∂x ∂x ∂x ∂x ∂x ∂N 3 ∂N 8 ∂N 2 ∂T ∂N 1 = T1 + T2 + T3 ...
........11) can be written as [K c ] = ∫ ∫ ∫ K −1 −1 −1 1 1 1 B T B J d ξ dη dζ (4..... ..... .... B T is the transpose of B matrix........ ∂z ∂z 3×8 T 7 T8 8×1 ∂T ∂N 1 ∂x ∂x ∂T ∂N = 1 ∂y ∂y ∂T ∂N 1 ∂z ∂z Using the above relations equation (4............. The Local Coordinate System associated with parent element is called curvilinear coordinate................. ∂x ∂x T3 T4 ∂N ∂N 2 .... The Serendipity coordinates for elements are represented as: x = ∑ M i xi i =1 nc 44 ...... 8 ∂y ∂y T5 ∂N 8 T6 ∂N 2 .................. The parent element may be selected from lagrangian / serendipity family. the above relations can be represented as: T1 T ∂N 8 2 ∂N 2 ..... ∂y ∂N 8 .........12) Where B matrix is given as ∂N1 ∂x ∂N B= 1 ∂y ∂N1 ∂z ∂N 2 ∂x ∂N 2 ∂y ∂N 2 ∂z ∂N 8 ∂x ∂N 8 .................. ............................ ∂z ..........In matrix form.......... To achieve the close boundary representation the scientists have developed curvilinear side element based on transforming simple geometric shapes of some local coordinate system into distorted shapes in global Cartesian system and then evaluating the element equation for the distorted element.......
+ . So by using chain rule differentiation ∂N i ∂N i ∂N i ∂N i ∂x ∂y ∂z = . The derivative cannot be found out directly as shape function is expressed in terms of natural coordinates ( ξ . . + . . ∂ζ ∂x ∂ζ ∂y ∂ζ ∂z ∂ζ ∂N i ∂x ∂ξ ∂ξ ∂N i ∂x = ∂η ∂η ∂N i ∂x ∂ζ ∂ζ ∂y ∂ξ ∂y ∂η ∂y ∂ζ ∂z ∂ξ ∂z ∂η ∂z ∂ζ ∂N i ∂x ∂N i ∂y ∂N i ∂z The final heat transfer equation can be written as [[K ] c + [K h ] {T } = ] {Rh } 45 . ζ ). Now to evaluate the B–matrix we need to evaluate the derivative of shape function with respect to x. ∂ξ ∂x ∂ξ ∂y ∂ξ ∂z ∂ξ ∂N i ∂N i ∂N i ∂N i ∂x ∂y ∂z = + + .η . x = ∑ N i xi i =1 8 8 y = ∑ N i yi i =1 8 z = ∑ N i zi i =1 Here.η . Mi = Ni Therefore. ζ ). + . Ni is a function of ( ξ . nc = Total number of nodes per element and for isoparametric elements.y = ∑ M i yi i =1 nc nc z = ∑ M i zi i =1 Here. y and z. ∂η ∂x ∂η ∂y ∂η ∂z ∂η ∂N i ∂N i ∂N i ∂N i ∂x ∂y ∂z = . + .
C2. Relationship between temperature and thermal softening can be given by [18] H (T ) = C1T 3 + C 2 T 2 + C 3T + C 4 Where H is hardness of cutting tool material.The above equation can be further written in the form as given below [K ]{T } = {Q} Where [K] = Thermal conductance coefficients matrix {T}= Nodal temperature vector.13) 4.H. 46 . • The value of elemental matrices [Kc] and [Kh] are calculated in functions stiff( ) and convection_stiff( ) and they are added appropriately to find L. {Q}= Nodal heat flux or heat load vector.5853.0054. of the equation 4.S. which are thus used in function hardness( ) to calculate the value of hardness at different nodes.4 HARDNESS OF TOOL Since effects of temperature are being considered on flank wear. and C4 are constants for tool material. C4=1517 4.000006. T is temperature in oC and C1. so it becomes necessary to consider thermal softening of cutting tool material. • • • The [Rh] matrix is calculated as per equation in function load( ) Appropriate boundary condition are applied in boundary( ) and then the global {T} vector is calculated from function solver( ).10 and 4. For carbides tool the values for these are: C1 = 0. The function separate( ) gives the values of {T}. C3.5 SOLUTION SCHEME • The threedimensional solution domain corresponding to tool bit is discredited for the solution of the final heat conduction equation (4. C3 = 0.12 respectively. C2 = 0. (4.13) and appropriate boundary conditions are applied.
h_data( ) Read 3D mesh data and boundary condition Call stiff( ) Generate [Kc] matrix equation (2) Call connection_stiff( ) Generate stiffness matrix due to convection boundary condition Call load( ) Generate R.S of equation (vector {Rh}) Call boundary( ) Call solver( ) Call separate( ) Call Hardness( ) STOP 47 .H.4.6 FLOW CHART OF SOLUTION PROCEDURE START Call data( ).
08 0. The EN24 steel workpiece material has been used for experimentation. for the measurement of the temperature. that is for the solution of the thermal softening of the tool material in order to predict the tool wear have been developed in accordance with the previously developed models for tool wear [4]. This predicted temperature is than related with the hardness of the cutting tool (Thermal softening).5 RESULTS AND DISCUSSIONS In the present chapter the results for the present problem. This temperature of contact area have been used to determine the overall temperatures at the various parts of the cutting tool using the heat transfer equation developed and using the FEM methods for the solution of these equations for the present problem with the appropriate boundary condition as has been explained in chapter 4. that have been selected for experimentation. Using the experimental data. The number of experiments has been conducted to find out the cutting forces and flank wear of the tool.1: Cutting parameters Cutting speed v (rpm) (Range) 420 710 Feed f (mm/rev) (Range) 0.1 shows the numerical values of the various machining parameters (cutting speed. 5. feed and the depth of cut). which have been ultimately used to determine the modified temperature at the tool and the workpiece contact area. and its specifications have been 48 .CHAPTER .1 MACHINING PARAMETERS USED FOR EXPERIMENTATION Table 5. The measured experimental values are than fed into the FEM program to predict the temperature at all the nodes of a cutting tool. at varying machining parameters.75 The table 5.16 Depth of cut d (mm) (Range) 0. cutting feed (f) and depth of cut (d). strain rate and flank wear. made of tungsten carbide.5 0. which are cutting speed (V). [20] and [22]. For simplicity the tool is assumed to be a single point with zero nose radius. the strain rate and average interface temperature for the various cutting conditions have been obtained.
The levels of the process variables. The cutting material used is Tungsten Carbide.065 0. Tool edge has been made straight or parallel to the chuck to have an orthogonal cut. This has been done so that all the measurements should be taken correctly at the same operating conditions to have a good accuracy in results with minimum possible error. strainrate and resultant cutting forces for different speed. and its specification has been mentioned in appendix C. feed and depth of cuts for the different set of experiments conducted on the carbide cutting tool. The relationship between machining parameters and temperature generated at tool workpiece interface has been calculated using the empirical relations as mentioned in the references [4].03 0. 1 stands for the minimum.02 0. are in between the [1. the tools have been replaced after every cut of constant volume of workpiece material.075 Strain Rate(exp) 1s1 577 569 165 550 840 880 820 830 Resultant Forces (N) 340 410 470 560 245 500 390 398 To eliminate the effect of wear on the experiments. Here. [24].2: Experimental Results of measured parameters against parameters V. which have been used for the experiments of the validation set. Constant volume signifies that equal amount of material was removed in all the different sets of experiment conducted. and +1 stands for the maximum level of parameters. Table 5.035 0.2 shows the experimental values of wear.025 0.045 0. v d f Wear(exp)in mm 1 2 3 4 5 6 7 8 1 1 1 1 +1 +1 +1 +1 1 1 +1 +1 1 1 +1 +1 1 +1 1 +1 1 +1 1 +1 0.shown in appendix B. Strain rate has also been measured using the empirical relations and than both the measured temperature and the strain rate 49 . In total eight carbide bits have been used for all the different set of experiments to be conducted.05 0. The temperature at tool tip was calculated by changing different depth of cut. and [26]. The table 5. feed rate and cutting velocity. No. 1] range. f and d S.
The following are the details of the discritization of the solution domain carried out for the FEM Analysis and thus used in the developed computer program for the generation of the results. 5. considering heat loss because of conduction in the tool material and convection with air at ambient temperature. This temperature has been applied to analyze the temperature distribution on the tool at different edge. nodes and elements through finite element analysis. Tool material hardness has been calculated with the help of the temperature distribution obtained as a result of FEM analysis [18]. mathematical expressions have been derived and discussed in the previous chapter and have been used to predict the temperature at the various locations of the cutting tool.are put into the equation to find the modified temperature which considers the effect of both. Problem is for Type of elements Total node Total element Node per element Node per face Number of fixed nodes : 3 D heat conduction : Eight Noded brick elements (Serendipity family) : 288 : 168 :8 :4 : 3 (temperature at the tip of the cutting tool) Number of convection Faces : 6 (shown in Appendix–C) 50 . The results have been obtained for tool wear with the change in machining parameters by relating the heat generated at the toolworkpiece interface and taking hardness of tool material as a function of temperature [18]. Computer program in VC++ environment based on the FEM formulation presented in the previous chapter have been developed and numerical results for temperature and its effect on the hardness of the cutting tool have been obtained and discussed in preceding topics.2 MODELLING OF SOLUTION DOMAIN USING FEM In order to use the finite element technique.
and have been compared with the results of Leshock et al [4]. have been calculated 51 . as the maximum variation in the results is only of the order of 5. Using the mathematical model for modified cutting temperature as discussed in section 4. that as we move away from the flank edge. the three different values of modified cutting temperatures 750 K. It is interpretable from the graph. As at the tool tip the temperature is maximum. The results from the reference are well in accordance with the results of the present work. T∞ =27oC (for air).8 %.2.2 shows the relation of tool hardness with the flank distance at different temperature distribution on flank edge of the carbide tool bit.1: Relationship between Cutting tool temperature and flank distance In order to check the validity of the analysis and the solution procedure discussed in chapter 4.18. γ = 1 s −1 . the temperature keeps on decreasing and thus the tip of the carbide cutting tool is prone to more wear rather than the distances away from the tool tip. therefore the hardness is less. 900 K.1. 5. K = 0. 5.1.3 VALIDATION OF RESULTS Figure 5. The relation between flank edge distance and the final temperature variation on the cutting tool have been developed for the range of the cutting parameters as given in the table 5.076 W/m2k . for checking the validity of the results.4 VARIATION OF HARDNESS WITH FLANKEDGE DISTANCE The figure 5. and 1050 K.The properties of the cutting tool used (Carbide bits) are: ν = 0. the results for temperature field and its effect on thermal softening of cutting tool have been obtained from the developed computer program by using the experimental data of strainrate and flank wear. and have been shown here in graphically form in figure 5.
00 1. 1600 1400 Hardness (BHN) 1200 1000 800 600 400 200 0 0.2: Relation between hardness and flank distance 5. Temp. 830 s1. corresponding to the different values of feed.from the corresponding strainrate values which are 840 s1.1.3 shows the variation of temperature with the cutting force. At the same flankedge distance. we have different hardness values along the flank face of the tool.00 2. for these values of modified cutting temperatures. at tip = 1050 Temp at tip = 900 Temp at tip = 750 Flank Edge Distance (mm) Figure 5.00 0.5 VARIATION OF TEMPERATURE WITH CUTTING FORCE 1400 1200 Temperatures ( oK) 1000 800 600 400 200 0 200 300 400 500 600 700 Temperature (K) M od.50 2.3: Variation of Temperature with resultant cutting force The figure 5.50 Temp. As shown in the graph. speed and depth of cut as shown in table 5. and 577 s1 respectively. The temperature starts decreasing because of heat loss as we move away from the tool tip along the flank surface the hardness of material increases. (K) Resultant Force(N) Figure 5. as the cutting forces increases the temperature at the tip of the cutting tool also increases due to higher frictional forces at the tip of the carbide tool bit. This 52 .50 1.
4: Variation of Flank Wear with the resultant cutting force The figure 5.7 VARIATION OF FLANK WEAR WITH MODIFIED CUTTING TOOL TEMPERATURE Figure 5.increased temperature of the tool leads to the reduction of hardness value of the cutting tool and thus the tool wear.6 VARIATION OF FLANK WEAR WITH CUTTING FORCE Figure 5. This is because increase in forces leads to increase in the temperature of the cutting tool as shown in figure 5. 5.5: Variation of flank Wear with respect to modified temperature 53 . As shown the flank wear of carbide insert increases with the increase in the forces during the bar turning process. 5.3 and increased temperatures further leads to the flank wear of the cutting tool due to the thermal softening.4 shows the variation of the wear with the cutting tool Force.
D = 1.5 shows the variation of the wear with the modified cutting tool temperature due to the strain rate.8 REGRESSION EQUATION Regression equations obtained from the experimental data of a bar turning process using carbide insert were obtained using Data Fit software Version8.x developed by Oakdale Engineering.50 0. 6: Relation between Cutting velocity and temperature at feed rate (f = 1) 54 .The figure 5. 5. Wear (mm) = e (A×f + B×d + C×f + D) A = 1. f and d are levels of cutting speed (v).00 1. C = 2.045. feed (f) and depth of cut (d) respectively and values for these levels can be obtained by following Formula: Level = (actual value in the range . d) is as follows.50 1.6.44 × e15 .00 0.50 d = 1 d = +1 1. B = .015 × e16 .0.50 Cutting Velocity at f 1 Figure 5.00 0.9 VARIATION OF TEMPERATURE WITH CUTTING VELOCITY 1400 1200 Temperature (K) 1000 800 600 400 200 0 1. The regression equation relating tool flank wear of a carbide insert with cutting parameters (V. and thus to the flank wear of the carbide cutting tool. As shown the flank wear of carbide insert increases with the increase in the temperature of the cutting tool.612 × e15 Where v. As increased temperatures at the tip of the cutting tool leads to the reduction of the hardness value.mean value of the range) (Difference Between maximum and middle level) 5. that is the thermal softening. f.
6.6 shows a relation of cutting velocity versus temperature. at constant feed at different levels depth of cuts used in experimentation work. It shows temperature increase with increase in depth of cut.The figure 5. from these trends it’s depicted that with the increase in velocity of cutting. Figure 5. The figure 5.7 depicts the same trends as figure 5. The inference that can be drawn from the above graph is that when we increase the cutting velocity the temperature keeps on increasing.7: Relation between Cutting velocity and temperature at feed rate (f = +1) The figure 5.8: Variation of Temperature versus cutting velocity at depth of cut (d = 1) 55 . These two graphs are at constant depth of cuts for each curve. the temperature raises. Figure 5.8 shows results of temperature with cutting velocity at constant depth of cuts.
10 trend of cutting velocity with wear has been shown at constant feed of 1. that is the lowest feed taken in experiments at different depth of cuts 56 .50 f = 1 f = +1 1.50 1.9: Variation of Temperature versus cutting velocity at depth of cut (d = +1) Similarly figure 5.10 VARIATION OF FLANK WEAR WITH CUTTING VELOCITY (FOR CONSTANT FEED RATE) Figure 5.1400 1300 Temperature (k) 1200 1100 1000 900 800 700 600 500 1. 5. The trend line is depicted to be same as it increases with rise in velocity of cutting.9 shows the graph but at different machining parameters and conditions (d = +1). In figure 5.50 0.00 0.50 Cutting Velocity at d =+1 Figure 5.10: Variation of flank wear with cutting velocity at constant feed rate (f = 1) Here the results have been shown for the variation of wear with the cutting velocity of the tool.00 0.00 1.
01 0 1.50 1.04 0. The figure 5.03 0.02 0. for better understanding of wear trends graphs are also shown at constant depth of cuts. 0.50 0. The results seem almost similar for this case too.12 shows results of wear with cutting velocity at constant depth of cuts.015 0.02 0.00 0.05 0.035 Flank wear(mm) 0.11 VARIATION OF FLANK WEAR WITH CUTTING VELOCITY (FOR CONSTANT DEPTH OF CUTS) The graphs discussed till now were at constant feed rate.50 0.00 1.00 0.50 1.06 0.005 0 1.07 Flank wear(mm) 0.12: Variation of flank wear with cutting velocity at constant depth of cut (d = 1) 57 . 0.00 0.00 1. The figure 5.50 d = 1 d = +1 Cutting velocity at f =+1 Figure 5.03 0.shows almost same pattern of increasing flank wear with increase in velocity.50 1.00 0.01 0.50 f = 1 f = +1 Cutting velocity at d=1 Figure 5.025 0.50 1.08 0.04 0.11 depicts same trends of wear but here now feed rate is (f = +1).11: Variation of flank wear with cutting velocity at constant feed rate (f= +1) 5.
the following conclusions have been observed: 1. because heat generated increases with increase in the strain rate. 2.00 0. The flank wear is directly proportional to the resultant cutting force and approximately follows a linear trend.07 Flank wear(mm) 0.50 1. 5. 3. The flank wear increases with increase in modified cutting tool temperature (due to increase in the strain rate). The contact temperature increases with the increase in the cutting velocity. The hardness increases with increase in distance from the flank edge and with decrease in the toolworkpiece contact temperature.50 1. there is a significant increase in the contact temperature with 58 . that is with increase in the cutting velocity for some constant value of depth of cut. the tool wear increases. 5.08 0.06 0.03 0. but at constant cutting velocity.0.05 0. but do not follow a linear trend and thus we can find an optimum set of machining parameters to have a minimum heat generation at toolworkpiece contact. but there is a nonlinear trend so we can find an optimum value of cutting parameters so as to give minimum strain rate.02 0.00 1.00 0. The change in the tool workpiece contact temperature depends upon the cutting parameters and it increases with increase in resultant cutting force.50 0.04 0.13: Variation of flank wear with cutting velocity at constant depth of cut (d =+1) The figure 5.13 also shows similar results but at depth of cuts (d = +1).01 0 1. 4.12 CONCLUSIONS Based on the results presented in previous sections. The trend is almost same depicted in other graphs as shown before.50 f = 1 f = +1 Cutting velocity at d=+1 Figure 5.
drilling. Thus for getting still more accurate results we can take into account few more parameters as given below: • • • • • The transient analysis for the machining operation can be studied. 5. feed rate. Also at constant cutting speed it increases with increase in both feed rate and depth of cut. So there is always need for perpetual improvements. in such a way so as to have the optimum temperature at the tool tipworkpiece contact because of the heat generated. and thus we could have the longest tool life and better machining economy. 59 . and depth of cut. Thus finally it can be observed that we must select the cutting parameters. cutting tool and work material can be studied. CBN.increase in the depth of cut as compared to the increase in the contact temperature with the increase in the feed rate. The other combinations of machine. The presently developed system can be used for other conventional as well as unconventional processes such as milling. which are cutting speed. The study can also be extended on coated carbide tools. manufacturing systems in the industry are being driven more and more aggressively. or other harder tools. 6. so that the minimum tool wear is encountered. CNC machines can be used for the experimentation to have the better control of the process variables and also parameters can be set to the desired accuracy.13 SCOPE FOR FURTHER WORK With increasing competitiveness as observed in the recent times. The flank wear increases significantly with the increase in the cutting velocity.
7 mm/rev 0.69 25x25.APPENDIX .052.2KW/3 HP 1250 Kg 1035 mm 915x2725 mm 225 mm 125 mm 150 mm 53 mm dia Metric Short No. AC Supply 0. 415 V. 20x20 mm 420 mm dia 220 mm dia 550 mm dia 155 mm dia 200 mm 1000 mm 60 .54 mm/rev 2. 7 321200 rpm 1. 50 Hz.010.A SPECIFICATIONS OF THE CENTRE LATHE Center Height Center Distance Swing Over Bed Over Cross slide In Gap Gap Width Transverse Of Cross slide Of Top Of Tailstock Spindle Spindle Bore Spindle Bore Taper Spindle Speed Spindle Speed Ratio Tool Shank Size Feed Longitudinal Feeds Cross Feed Main Motor Weight of Machine Height of the Spindle Center above Floor Floor Space 3 Phases.
1.0.APPENDIX –B WORKPIECE SPECIFICATIONS • • Work piece material Work piece combination : : EN 24steel 0.0.45.9 .1 .45 %C 0.8 %Ni 0.35% Si And rest is Iron • • • Work piece hardness Cutting tool material Hardness : : : 260BHN K10 CARBIDE INSERT 1500 BHN 61 .0.1.3 .4 % Co 0.0.6 %Mn 1.2 .3 % Cr 0.35.
4.1: Convection faces used in FEM analysis of Carbide cutting tool Here 1. 5. 2. 62 . 3. 6 are the faces through which the heat is lost to the environment (convection heat loss).APPENDIX – C WORKPIECE SPECIFICATIONS 3 5 1 4 6 2 Figure AC.
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