An investigation of workpiece temperature variation in end milling considering flank rubbing effect

• Published in: International journal of machine tools & manufacture 2013-10, Vol.73, p.71-86
• Main Authors: Lin, Sen, Peng, Fangyu, Wen, Jie, Liu, Yizhi, Yan, Rong
• Format: Article
• Language: English
• Subjects: Computer simulation; Cutting; End milling; Flanks; Machine tools; Machining; Mathematical analysis; Mathematical models; Thermal modelling; Tool flank wear; Workpiece temperature; Workpieces
• ISSN: 0890-6955; 1879-2170
• DOI: 10.1016/j.ijmachtools.2013.05.010

Better prediction about the magnitude and distribution of workpiece temperatures has a great significance for improving performance of metal cutting process, especially in the aviation industry. A thermal model is presented to describe the cyclic temperature variation in the workpiece for end milling. Owing to rapid tool wear in the machining of aeronautical components, flank rubbing effect is considered. In the proposed heat source method for milling, both the cutting edge and time history of process are discretized into elements to tackle geometrical and kinematical complexities. Based on this concept, a technique to calculate the workpiece temperature in stable state, which supposes the tool makes reverse movement, is developed. And a practicable solution is provided by constructing a periodic temperature rise function series. This investigation indicates theoretically and experimentally the impact of different machining conditions, flank wear widths and cutter locations on the variation of workpiece temperature. The model results have been compared with the experimental data obtained by machining 300M steel under different flank wear widths and cutting conditions. The comparison indicates a good agreement both in trends and values. With the alternative method, an accurate simulation of workpiece temperature variation can be achieved and computational time of the algorithm is obviously shorter than that of finite element method. This work can be further employed to optimize cutting conditions for controlling the machined surface integrity. •An investigation is presented to describe the workpiece temperature variation in end milling under different process conditions with sharp and worn tools.•Based on theoretical and experimental results, the rule of cycle temperature variation with the movement of cutting tool can be achieved.•In order to solve problems of geometrical and kinematical complexities in modelling milling temperature distribution, both the geometry of cutting tool and time history of process are discretized in the proposed heat source method.•The proposed reverse integration method supposing the tool makes reverse movement, which is suitable for the stable state, can shorten computing time strongly by constructing a periodic temperature rise function series.•The influences of the flank wear and cutting parameters on workpiece temperature are indicated, which can be used for controlling cutting forces and workpiece temperatures.