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Modeling and verification of temperature rise during machining

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Modeling and verification of temperature rise

during machining

Prabhat Chand Yadav, Sandeep Sahu & Shashank Shekhar

To cite this article: Prabhat Chand Yadav, Sandeep Sahu & Shashank Shekhar (2019): Modeling
and verification of temperature rise during machining, Journal of the Chinese Advanced Materials
Society, DOI: 10.1080/22243682.2018.1556333

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JOURNAL OF THE CHINESE ADVANCED MATERIALS SOCIETY
https://doi.org/10.1080/22243682.2018.1556333

Modeling and verification of temperature rise

during machining
Prabhat Chand Yadav, Sandeep Sahu and Shashank Shekhar
Department of Materials Science and Engineering, Indian Institute of Technology Kanpur,
Kanpur, India

ABSTRACT ARTICLE HISTORY

The temperature rise in chips during machining process largely Received 26 March 2018
affects the tool life as well as the quality of the machined prod- Revised 3 December 2018
uct. It also affects the power required for machining. Therefore, Accepted 3 December 2018
accurate measurement of temperature rise in chips during
KEYWORDS
machining is important not only to understand and predict any Machining; infrared camera;
changes in the properties of the component but also to predict thermal imaging technique
and optimize the life cycle of the tool. In this work, we measure
temperature rise during shaping process of the aluminum block
using thermal imaging technique and compare the values with
that obtained using Weiner’s model for moving heat source. Our
result indicates that temperature value obtained by the infrared
camera was very close to those obtained by Weiner model. This
work validates the use of Weiner model for an in situ temperature
rise of chips during machining.

1. Introduction
During the deformation process, energy dissipates in the form of heat, which is
known as low-grade energy.[1,2] This energy in the form of dissipated heat directly
affects the microstructure and hence, the performance of the component being manu-
factured. During machining, shear zone, tool–chip interface, and tool–work interface
are the primary heat affected zones.[3,4] It is imperative to understand the source of
this temperature rise and literature suggests that approximately 80% of the total heat
generated during machining is dissipated through chips. Therefore, the temperature
rise in heat affected zone directly affects the properties of the tool as well as the
workpiece material. Meanwhile, the temperature rise also degrades the tool wear
behavior because of adhesion between tool and chip at elevated temperature. So, tem-
perature rise plays an important role in the estimation of tool life. Hence, in order to
obtain better tool life prediction and properties of the workpiece material, optimized
machining conditions should be used. Numerous research work has been carried out
to measure temperature rise in the workpiece and tool during the machining process.
Jaspers et al. [5] performed orthogonal machining on steel and obtained a

CONTACT Shashank Shekhar shashank@iitk.ac.in Department of Materials Science and Engineering, Indian
Institute of Technology Kanpur, Kanpur 208016, India
ß 2019 Chinese Advanced Materials Society
2 P. C. YADAV ET AL.

temperature distribution in the chip by assuming a certain heat flux (entering the
chip) profile. They concluded that the temperature changes more significantly with
cutting speed compared to feed rate. In continuation of temperature measurement,
Hummel et al. [6] also suggested that for determining accurate temperature rise, not
only knowledge of emission coefficient but also variation of emission coefficient with
temperature is necessary. Likewise, Korkut et al. [7] also performed a detailed and
systematic study of the effect of cutting parameter on chip temperature rise measure-
ment during the machining process. They noticed drastic increment (40–60%) in
chip temperature on increasing the depth of cut by two-fold while approximately
similar increase in feed rate leads to <10% increase in chip temperature.
Temperature rise during plane-strain machining was also examined by Prakash et al.
[8] with the help of Weiner model [9] and they found significant enhancement in
temperature with cutting speed using a negative rake angle tool. However, they did
not verify the accuracy of the model.
Systematic studies have also been carried out to examine temperature rise via ana-
lytical models and simulations of the machining process and validated by different
techniques. Dogu et al. [10] developed a model to understand the thermal aspect of
the workpiece and tool material. They obtained maximum temperature at half of the
contact length from the edge of the tool tip at lower cutting speed. Many authors
have also examined temperature rise using different computational methods. Most of
them have utilized finite element method (FEM) simulation to obtain temperature
rise in the chip. Kim and Shin [11] developed a cutting model using FEM to study
the forces required during orthogonal cutting process with the understanding that
flow stress of a material is a function of temperature. They validated their simulated
outcome with experimental result and obtained good correlation. Temperature rise
obtained using this model was also validated by Tay et al.’s results.[12] Komanduri
et al. [13] did another detailed simulation work on temperature rise distribution by
considering the effect of heat source at the shear plane and frictional heat at tool–-
chip interface. After comparing the simulated value with experimental results pre-
sented in literature, they found a good correlation at the same machining condition.
However, in most of the studies mentioned above, experimental verification involved
measuring temperature only at shear plane rather than at tool–chip interface which is
perhaps the major heat source. Moreover, the models that have been applied are
rather complex and need heavy computation to obtain temperature rise. While they
are necessary to obtain temperature field, if one is interested in only the average tem-
perature, then a simple analytical model is sufficient.
In the experimental methods that have been utilized to verify the temperature rise,
there have been several lacunae, the most prominent being the spatial resolution of
the techniques involved. Dewes et al. [14] investigated the temperature rise using
thermocouple and infrared camera to examine the temperature difference. They
observed lower value of temperature rise using infrared camera than that obtained
using thermocouple. It was suggested that this was due to heat loss from the tool as
well as workpiece. It is also plausible that the infrared camera did not have sufficient
resolution and contributed to the error in measurement. If each pixel of the camera
does not represent a sufficiently small region on the workpiece, the maximum
 JOURNAL OF THE CHINESE ADVANCED MATERIALS SOCIETY 3

Table 1. Composition of aluminum alloy used in the machining process.

Element Al Si Cu Mg Fe Mn Ti Cr
Composition (wt %) 98.2 0.582 0.072 0.001 0.842 0.005 0.016 0.002

temperature corresponding to a particular point cannot be exactly determined. A

larger pixel will measure an average of a larger region and hence, will show a lower
temperature than the maximum temperature within that region. Even thermocouples
have very poor spatial resolution and measure the average temperature of the region
of 0.1 mm, at best. Moreover, thermocouple must be placed at the appropriate place
to be able to extract maximum temperature rise. In fact, Ng et al. [15] showed using
FEM simulation that maximum temperature has a very sharp distribution at the
tool–chip interface. In their own work, they found that the experimental technique
used for measuring the temperature rise had limited spatial resolution and a sharp
temperature value could not be obtained at that particular point (tool–chip interface).
As mentioned above, the major lacunae in validating the temperature rise, is three-
fold: (a) Most of the studies have measured temperature at shear plane and not at the
tool–chip interface, where highest temperature rise can be expected; (b) in most of the
experimental studies, the camera used for obtaining temperature rise probably did not
have sufficient spatial resolution, which is major hurdle for validating the temperature
rise. Moreover, at high temperature, measurement becomes difficult because of the lack
of suitable camera which can provide good thermal sensitivity, good thermal resolution
as well as spatial resolution; and (c) the mathematical models that have been used to
predict temperature rise are relatively complex. In order to allay these drawbacks, we
used Weiner’s moving heat source model [9] to predict the temperature rise at the
tool–chip interface, which is very simple and easy to compute analytical model.
Moreover, the values obtained from this model were experimentally validated by meas-
uring the temperature rise at the tool–chip interface using infrared thermography. The
spatial resolution of thermography is usually limited by the lens set up and diffraction
conditions. For a configuration like ours, theoretical resolution limit can be shown to
be 3 lm (taking a working distance of 9.2 cm). We used FLIRX6540SC camera which
allows good spectral resolution (
32  32 lm) and a good range of thermal sensitivity
<25 mK (typically 20 mK). We used the aluminum block as our workpiece which was
placed on a shaper machine to conduct the experiment.

2. Experimental procedure
2.1. Workpiece material
In the current study, aluminum alloy was selected as a workpiece for the machining
process. The composition of the aluminum alloy obtained using optical emission
spectroscopy (OES) is shown in Table 1.

2.2. Machining process

The machining was performed on rigid instrumented shaper machine with power 2
kW and constant machining speed of 250 mm/s. The schematics of machining setup
4 P. C. YADAV ET AL.

Figure 1. Schematic of the machining process along with thermomicrograph in grayscale.

Table 2. Details of infrared camera used in machining aluminum block.

Specification Camera Specification Detector
Camera model FLIR X6540SC Spatial resolution 32 mm (with 9.2 cm
working distance)
Frame rate 100 Hz Full frame (10 ms) Pixel pitch 15 mm
Integration time 537 ms IR resolution 640  512
Lens 50 mm þ extension ring Sensor material InSb
Aperture F/2.0 Detector type Focal plane array (FPA)
Thermal sensitivity <25 mK F-number F/3
Theoretical accuracy ±1  C Integration time step 160 ns
Accuracy with real radiometric ±4  C
data (emissivity ¼ 0.18)

with thermomicrograph in grayscale is shown in Figure 1. Machining parameters like

feed (0.275 mm/rev), depth of cut (1.0 mm), and rake angle of the tool (20 ) were
kept constant throughout the process to get constant strain and strain rate, which
were found to be
3.0 and
940/s, respectively. The heat capacity of aluminum was
taken as 2.40 MJ/m3  C.[16] After machining with constant parameters, aluminum
chips having average final thickness
0.40 mm were obtained in one complete run of
the tool. The hardness of the starting aluminum block and machined chips was found
to be
23.2 VHN and
71.54 VHN, respectively. The drastic enhancement in hard-
ness value ensures that the process is severe plastic deformation and hence, large
microstructural transformation takes place during the process. Similar results in hard-
ness were also observed in our previous research work.[17,18] Simultaneously, ther-
momicrograph of chips along with machining tool at particular instants was recorded
frame by frame using thermal imagining technique by infrared camera (model no.
FLIR X6540SC). Details of the infrared camera used in the current study are shown
in Table 2. After calculation, it was found that the size of each pixel was
32 lm.
The camera was focused on the zone considering tool tip and workpiece contact in
the machining configuration. For better visibility, the rainbow color scale was used
during recording of the image. Proper estimation of emissivity is important in deter-
mining the temperature rise accurately. Emissivity measures an object’s ability to emit
radiation, and its value can vary between 0 and 1.0 (for blackbody). After careful
study of the literature about our work material, we used an emissivity of 0.18 for our
 JOURNAL OF THE CHINESE ADVANCED MATERIALS SOCIETY 5

Figure 2. Step-by-step movement of the tool on the workpiece during the machining process.

workpiece.[19] The frame by frame movement of the High-speed steel (HSS) tool on
the aluminum workpiece during machining is shown in Figure 2.

3. Results and discussion

3.1. Shear strain
Shear strain is the most important parameter used in the calculation of chip tempera-
ture rise in the machining process. Therefore, shear strain in the chip and hardness
was calculated which are used as starting data for temperature rise calculation. Shear
strain in the material was calculated by knowing the rake angle of the tool which is
20 in the current study.
Shear strain was calculated using Equation (1):
cosa
Y¼ (1)
sinØ cosða  ØÞ

where shear angle (Ø) was obtained by following equation [1,20–22]:

0
 1
a0
cosa
B a
C
Ø ¼ tan1 @
c
 A (2)
1  aa0c sina

C:Vs
Strain rate ¼ (3)
1:732XL
where Y is the shear strain, a0 is the feed rate, ac is the depth of cut, a is the rake
angle and Ø is the shear angle, C is a constant taken as 4.8,[21] Vs is shear velocity
and L is the length of deformation plane.
6 P. C. YADAV ET AL.

Shear velocity was obtained using the following equation:

Uwork cosa
Vs ¼ (4)
cosðØ  aÞ

where L (length of deformation) is given by

a0
L¼ (5)
sinØ

3.2. Temperature rise calculation using Weiner model

The temperature rise in the tool–chip interface is the direct result of heat generated in
the chip. Rise in temperature during machining is mainly due to a larger amount of
strain in shear zone and friction force dissipated during machining which is generated
due to relative motion between tool–chip as well as tool–workpiece interface. Therefore,
the temperature rise in chip was calculated using the following equation [20]:
 
ð1bÞKY a sav Uchip l Kwork 0:5
DT ¼ þ 0:75 (6)
qc Kwork Uchip l

where the first term of above equation corresponds to average temperature rise
due to primary shearing and latter part corresponds to average temperature rise due
to friction heating. Significance of average temperature rise due to friction heating
can be gauged using time of contact of chip with cutting tool. Here, the chip is in
contact with cutting tool for marginal time. Hence, temperature rise due to friction
heating was neglected, and the final equation reduces to:

ð1bÞKY
DT ¼ (7)
qc

where qc is the heat capacity of the work material (2.40 MJ/m3  C), K is the shear
flow stress, calculated by the hardness of the chip (VHN) which is given by ry=HV/3
and using Von Mises model, K=ry/冑3.
b is the partition parameter, which denotes the fraction of heat taken away by the
bulk workpiece. This parameter can be obtained using Weiner model [9]:
 u   
1 pffiffiffiffi pffiffiffiffi e 1 pffiffiffiffi
b¼ erf u þ ð1 þ uÞe rfc u  p ffiffiffiffi pffiffiffiffi þ u (8)
4u P 2 u

Moreover, / is the thermal number, also given by Weiner [9]:

Uwork f  tan Ø
u¼ (9)
k

‘f’ is the feed rate in machining, k is thermal diffusivity of work material (0.86
cm2/s [23]) and Uwork is the speed of machining. The parameter used in
 JOURNAL OF THE CHINESE ADVANCED MATERIALS SOCIETY 7

Table 3. Details of parameters used in machining aluminum block.

Parameter b a c u tan Ø
Absolute value 0.099 2.48 3.01 0.482 0.523

determination of temperature rise during machining was calculated using the above
equations and shown in Table 3.
Therefore, using above equations, the temperature rise was found to be
148  C.
So, the average temperature of the chip can be given as
180  C after adding the
room temperature (32  C in present work) value to this temperature rise. This aver-
age temperature calculated by Weiner model was validated by the temperature rise
recorded by infrared camera.

3.3. Weiner model validation using thermal imaging technique

We have seen that the calculation of average temperature rise during machining of
aluminum block using Weiner model comes out to be
180  C. For validating
this calculation, we obtained the temperature rise in the machined chips via
thermal imaging technique by using the infrared camera (model no. FLIRX6540SC).
Figure 3(a) presents the details of a typical thermomicrograph obtained during
machining at a particular instant. Figure 3(b) shows the temperature profile w.r.t.
number of frames on tool–chip contact at a specific instant during machining. Peak
temperature region during machining is found near the center of the produced chips
(as shown in Figure 3(b)). However, this peak temperature region will keep on mov-
ing with time as the machining process continue and the chip going away from the
tool tip will keep on dissipating the heat in the environment. Maximum temperature
obtained using thermal imagining technique was found to be correlated with just 1 to
2 pixel having a pixel size
40 lm. The variation in temperature at different position
of the chip obtained using infrared camera has been shown through blue curve in
Figure 3(b). It shows that the peak temperature comes
178  C. However, this peak
temperature is intended for the very small region and at a very particular instant of
time. By looking at Figure 3(b), an average rise in the chip temperature is found to
be in the range of 150–175  C. Thus, it is seen that the temperature calculated using
Weiner model comes very close to that obtained using thermal imaging technique.
Prakash et al. also used this model [8] to obtain temperature rise during the machin-
ing process. They observed spherodization at the machined surface which generally
occurs at relatively higher temperature. Observation of spherodization validates the
temperature rise computed by them.
However, we caution the readers that the above model has some limitations. In
the above model, friction heating was neglected. However, if machining conditions
yield a thermal number >0.5, above assumption will not be valid, and there will be
significant temperature rise due to friction too. This implies that for very large values
of cutting velocity and/or very large feed-rate, our analytical model needs to be modi-
fied, to use extended form of Equation (6).
Another limitation of the model arises because of the Weiner model that was uti-
lized for obtaining the partition parameter. Literature shows that experimental and
8 P. C. YADAV ET AL.

Figure 3. (a) Details of a typical thermomicrograph obtained during machining at a particular

instant and (b) Temperature profile w.r.t. number of frames on tool–chip contact at a particular
instant during machining.

analytical result match only as long as the partition parameter is less than
0.9.[20]
Hence, only machining condition which results in partition parameter <0.9 should
be considered for applying this model.

4. Conclusion
In the current work, the average temperature of chips generated during machining of
aluminum block was calculated using Weiner model which comes out
180  C. The
temperature rise in chips was also obtained using FLIR infrared camera giving the
average temperature rise in the vicinity of 175  C, which is in good agreement to the
calculated value using Weiner model. Thus, this work validates the use of Weiner
model in measuring the in situ temperature rise during machining process which can
be very helpful in deciding suitable machining parameters to enhance the properties
of the machined material as well as the tool life.

Acknowledgments
The authors would like to acknowledge Pierre Bremond, FLIR Systems, Advanced Thermal
Solutions, Lingenfeld, France for providing Infrared camera at IIT Kanpur for measuring tem-
perature rise during the machining process. The authors would like to thank Mr. Surendra
Kumar Agnihotri, Department of Materials Science and Engineering, Indian Institute of
Technology Kanpur, India for help in conducting the experiment.
 JOURNAL OF THE CHINESE ADVANCED MATERIALS SOCIETY 9

Disclosure statement
No potential conflict of interest was reported by the authors.

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