Predictive modeling of cutting temperature and cutting force in high-pressure coolant jet machining

Abstract

The energy dissipated in machining operation is converted into heat which raises the temperature in the cutting zone. With the increase of cutting temperature; tool wear, surface roughness, dimensional inaccuracy increases significantly. Cutting force is also increased with tool wear which results the increase of power and specific energy consumption. Various researchers worked on various techniques to effectively control the increased cutting temperature as well as cutting force, tool wear rates, surface integrity. The cutting temperature, which is the cause of several problems restraining productivity, quality and hence machining economy, can be controlled by the application of highpressure coolant (HPC) jet. High-pressure coolant (HPC) jet cooling is a promising technology in high speed machining, which economically addresses the current processes, environmental and health concerns. Based on cutting condition, cutting environment and work/tool material the physical behavior during metal cutting has been changed. From an economic viewpoint, it is evident that having knowledge about the machining responses such as tool life, cutting forces, cutting temperature and work piece surface integrity at different cutting conditions would be highly desirable as a means of realizing cost savings, increased productivity, efficiency and for preventing any hazard occurring to the machine, cutting tool or the deterioration of the product quality. Optimization of process parameters for improving product quality, shortening processing time and reducing production cost is very important and for this purpose modeling of process parameters is necessary. By laborious and costly experimental investigation, machining responses like cutting temperature, cutting force, tool wear and surface roughness can be measured. Engineers and researchers have been realizing that efficient quantitative and predictive models that establish the relationship between a big group of input independent parameters and resultant performance are required for the wide spectrum of manufacturing processes, cutting tools and engineering materials currently used in the industry could contribute in industrial applications along with theoretical understanding. The aim of the present work is to investigate the role of high-pressure coolant jet in respects of chip formation, cutting temperature and force experimentally and then develop predictive models for cutting temperature and force in turning medium carbon steel (AISI 1060 steel) by uncoated carbide insert at industrial speed feed conbinations under high pressure coolant condition. The experimental results indicate that the performance of the machining under HPC condition is quite good and more effective compared to machining under dry condition. With the help of the experimental results, predictive models of cutting temperature and force have been developed to understand the basic phenomenon in metal machining. Prediction of cutting temperature has been conducted from analytical studies, where empirical correlations have been used to determine heat generation and temperature. Analytical calculations have been done under simplified assumptions. Using statistical analysis, predictive models of force has been developed. Finally, finite element model has been developed to evaluate temperature distribution by ABAQUS/CAE. The developed models satisfactorily validate its accuracy by comparing predicted values with experimental values.