Investigations On Transient Cutting Temperature Of Tool And Workpiece In High-speed Milling

High-speed cutting technology is one of most interesting manufacturing research areas, it is also the main direction of development of advanced manufacturing technology. The material removal mechanism is the basis of the high-speed cutting technology. The study of high-speed cutting temperature during material removal process is an important part of the high-speed cutting mechanism. Cutting temperature has a significant impact on tool life, tool wear and workpiece quality, which has become the research focus of high-speed cutting.In this paper, temperature in the high-speed milling process is researched based on the combination of analytical method, finite element simulation and experimental measurement. The impact of cutting speed in high-speed milling process on cutting temperature is identified and the existence condition of temperature breaking point is explored.First of all, an analytical model of transient cutting temperature of the milling insert rake face in the face milling process is established and validated by the experimental data from literature. The analyses of the impact of cutting speed on the insert rake face temperature show that the transient temperature in the rake face appears inflection point phenomenon when the cutting arc length of each tooth is certain, cutting velocity is fast to a certain extent and cutting time of each tooth is short enough in milling and other interrupted cutting processes. The temperature rises and reaches a steady-state when cutting continue and temperature inflection point phenomenon will disappear. Enough short cutting time is the basic reason of temperature inflection point phenomenon.Secondly, an analytical model of the workpiece temperature in the high-speed milling process is established based on the moving heat source method and inverse method. The accuracy of the model is verified by temperature measurement experiments of1045steel. Analyses and experimental results show that heat source strength and the feed speed have the largest impact on the workpiece temperature. The feed rate increasing and the heat flux flowing into the workpiece does not grow linearly as the cutting speed increases are the main reasons to cause the breaking point of the workpiece temperature.Then, two-dimensional high speed orthogonal cutting of super-alloy Inconel718and1045steel is simulated with the finite element software AdvantEdge. Cutting temperature trend with cutting velocity is analyzed with FEM. The simulated results show that the temperature on rake face declines when the cutting speed is higher than a critical value in the two-dimensional orthogonal cutting.Finally, the workpiece temperature of high-speed side milling process is measured using thermocouple sensor. The cutting temperature trend with cutting velocity of AerMet100and Inconel718in milling process is studied. The results show that the measured workpiece temperature beneath the machined surface shows a downward trend with non-wear insert and the increase in cutting speed,.This dissertation is supported by National Basic Research Program of China (2009CB724401) and Major Science and Technology Program of High-End CNC Machine Tools and Basic Manufacturing Equipment (2010ZX04017-012,2012ZX04003-041)...