Modeling and Monitoring of the Tool Temperature During Continuous and Interrupted Turning with Cutting Fluid

Abstract In metal cutting, a large amount of mechanical energy converts into heat, leading to a rapid temperature rise. Excessive heat accelerates tool wear, shortens tool life, and hinders chip breakage. Most existing thermal studies have focused on dry machining, with limited research on the effects of cutting fluids. This study addresses that gap by investigating the thermal behavior of cutting tools during continuous and interrupted turning with cutting fluid. Tool temperatures were first measured experimentally by embedding a thermocouple in a defined position within the tool. These experimental results were then combined with simulations to evaluate temperature changes, heat partition, and cooling efficiency under various cutting conditions. This work presents novel analytical and numerical models. Both models accurately predicted the temperature distribution, with the analytical model offering a computationally more efficient solution for industrial use. Experimental results showed that tool temperature increased with cutting speed, feed, and cutting depth, but the heat partition into the tool decreased. In continuous cutting, cooling efficiency was mainly influenced by feed rate and cutting depth, while cutting speed had minimal impact. Interrupted cutting improved cooling efficiency, as the absence of chips and workpieces during non-cutting phases allowed the cutting fluid to flow over the tool surface at higher speeds. The convective cooling coefficient was determined through inverse calibration. A comparative analysis of the analytical and numerical simulations revealed that the analytical model can underestimate the temperature distribution for complex tool structures, particularly non-orthogonal hexahedral geometries. However, the relative error remained consistent across different cutting conditions, with less error observed in interrupted cutting compared to continuous cutting. These findings highlight the potential of analytical models for optimizing thermal management in metal turning processes. Keywords: tool temperature; turning; cooling; cutting fluid; temperature simulation; analytical model; numerical model

相关文章

  • Hydrogel-based moisture electricity generators: materials, mechanisms, and sustainable device design
    [Chengyuan Zhang, Zhihua Yu, Zhibin Sun, Chengjing Ding, Qing Xu, Bingnan Xuan, Dong Liu, Jiangang Qu, He Shan, Mohammad Alamgir Hossain, Mingzheng Ge, Zhijie Liang, Jianying Huang, Yuekun Lai, Hui Liu]
  • Eco-Friendly Multifunctional Hydrogel Sensors Enabled Sustainable and Accurate Human-Machine Interaction System
    [Yanlong Zhao, Rui Wu, Yilin Hao, Yi Zhao, Xichong Zhang, Hui Liu, Wei Zhai, Kun Dai, Caofeng Pan, Chuntai Liu, Changyu Shen]
  • Highly Moisture-Resistant Flexible Thin-Film-Based Triboelectric Nanogenerator for Environmental Energy Harvesting and Self-Powered Tactile Sensing
    [Qinghua Liu, Yuyu Xue, Jinmei He, Jiehui Li, Leihuan Mu, Yue Zhao, Hui Liu, Cai-Li Sun, Mengnan Qu]
  • qq

    成果名称:低表面能涂层

    合作方式:技术开发

    联 系 人:周老师

    联系电话:13321314106

    ex

    成果名称:低表面能涂层

    合作方式:技术开发

    联 系 人:周老师

    联系电话:13321314106

    yx

    成果名称:低表面能涂层

    合作方式:技术开发

    联 系 人:周老师

    联系电话:13321314106

    ph

    成果名称:低表面能涂层

    合作方式:技术开发

    联 系 人:周老师

    联系电话:13321314106

    广告图片

    润滑集