Analytical model of workpiece surface temperature prediction in 4-axis milling process
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ORIGINAL ARTICLE
Analytical model of workpiece surface temperature prediction in 4-axis milling process Ruihu Zhou 1 Received: 2 July 2020 / Accepted: 15 October 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Milling temperature directly affects surface integrity and fatigue life, which is one of the important physical parameters in the process of machining. At present, the prediction of cutting temperature is mainly focusing on orthogonal cutting and turning; there is little research on the prediction of milling temperature of workpiece. The main idea is to discretize the cutting time and heat source, which is learning from the idea of milling force modeling. The moving heat source method is used to predict the workpiece temperature rise in milling process. The geometric kinematics of five-axis machining motion is analyzed. The temperature rise contribution can be calculated in the shear zone based on orthogonal cutting model through coordinate transformation. The proposed model is verified by experiments and 4-axis milling of cylinder surface temperature field is analyzed by simulation. This method can be extended to the temperature prediction of other processing methods, such as five-axis machining and turn-milling compound machining. Keywords Milling temperature . Analytical model . 4-axis milling
1 Introduction Temperature field affects the tool life, workpiece surface residual stress, and product fatigue life in milling process. Since milling is widely used in industry, the fast and precise thermal model is necessary to improve product quality and optimization cutting parameters. As reviewed by Abukhshim et al. [1], there mainly have three methods to develop cutting temperature model: numerical, experimental, and analytical methods. The thermal model of cutting process is based on heat conduction equation and boundary condition. In practice, the heat balance equations are partial differential equation and not have explicit expression solve expect especially conditions, so numerical method is used to solve equation such as finite element method (FEM). Pittalà et al. [2] used the Deform-3D software to predict workpiece face temperature field in milling operations. Nemetz et al. [3] used the FEM approach to model the milling process; 3D solid modeling is based on simplifying the 2D simulation results. The measurement methods of
* Ruihu Zhou [email protected] 1
School of Mechanical Engineering, Hubei University of Arts and Science, Xiangyang 441053, China
cutting temperature are summarized by Davies et al. [4]; thermocouple and infrared thermal imager measurements are widely used in lab and industry. Duazinski [5] used a K-type thermocouple and a J-type thermocouple to measure workpiece surface temperature field during dry peripheral milling. Augspurger et al. [6] used a thermocouple and a ratio pyrometer to measure the workpiece temperature in milling process. As the milling process is complex, the measured temperature is only average value in small zone when considering size eff
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