Three-dimensional temperature prediction in cylindrical turning with large-chamfer insert based on a modified slip-line field approach

Cheng HU, Kejia ZHUANG, Yuanwei TANG, Jian WENG, Xiaoming ZHANG, Han DING
2020 Chinese Journal of Aeronautics  
Chamfered inserts have found broader applications in metal cutting process especially in high-performance machining of hard-to-cut materials for their excellent edge resistance and cutting toughness. However, excessive heat generation and resulting high cutting temperature eventually cause severe tool wear and poor surface integrity, which simultaneously limits the optimal selection of machining parameters. In the present study, an analytical thermal-mechanical model is proposed for the
more » ... sed for the prediction of the three-dimensional (3-D) temperature field in cylindrical turning with chamfered round insert based on a modified slip-line field approach. First, an innovative discretization method is introduced in a general 3-D coordinate system to provide a comprehensive demonstration of the irregular cutting geometry and heat generation zones. Then, a plasticity-theory-based slip-line field model is developed and employed to determine the intensities and geometries of every elementary heat sources in Primary Deformation Zones (PDZ), Secondary Deformation Zones (SDZ) and Dead Metal Zones (DMZ). At last, a 3-D analytical model is suggested to calculate the temperature increases caused by the entire heat sources and associated images. The maximum cutting temperature region predicted is found existing upon the chip-tool contact area rather than the tool edge. Moreover, the rationalities of cutting parameters employed are analyzed along with theoretical
doi:10.1016/j.cja.2020.06.011 fatcat:pqht7x3hgvc5ljf7llxosoulum