Thermal Modelling of Orthogonal Machining Process

Abstract

Using analytical method based on Jaeger s heat source analysis and modified Blok s heat partition method the temperatures at different positions on chip, work piece and tool are newlinecalculated. The temperatures at tool-chip interface and chip-work piece interface are evaluated. The data is taken from longitudinal turning in orthogonal form using En-8 steel as work piece material and ISO6R2020 P30 cutting tool(Sandvik make) in dry environment. Evaluation of tool-chip interface temperature is important as maximum temperature newlineoccurs here. The magnitude and location of this maximum temperature is evaluated for same machining data with reference to different shear angle predication relations and contact lengths. The heat partition factors at this interface analyse using Liang s approach (modified newlineversion of Blok s heat partition principle). This modified approach gives more accurate temperature profile compare to functional analysis approach. When shear angle is predicated based on Lee-Shaffer relation and contact length based on dimensional analysis model with newlineboth uniform intensity heat source and non-uniform intensity heat source, the maximum temperature is located exactly middle of contact length. The Merchant s second solution based shear angle and contact length models (one based on dimensional analysis and second newlinemost frequently used) gives maximum temperature located at the end of contact length away from tool tip. newline