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Heat-flow determination through inverse identification in drilling of aluminium workpieces with MQL

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Abstract

One of the current trends in machining is the reduction or elimination of the use of cutting fluids to reduce economic and ecological costs. As a consequence, heating of the workpieces is increased, leading to greater thermal distortion. This distortion can be predicted using the finite-element method (FEM), provided heat input to the workpiece for the machining operation is known. The aim of this research is to determine the quantity and ratio of heat generated in drilling operations and to quantify the heat transferred to the workpiece based on cutting speed and feed rate. Thus, a detailed study of workpiece heating during the drilling process with minimum quantity of lubricant was conducted, and a combination of experimental and numerical data was used to obtain these parameters. The experiments were carried out on aluminium (Al2017) samples. Drilling torque and temperature of the workpiece were measured. The cutting procedure involved drilling a Ø10 × 15 mm blind hole using uncoated cemented carbide tools. Temperature was measured by infrared methods, and cutting torque was obtained using a piezoelectric dynamometer. The FEM model was developed using the general-purpose software ABAQUS/Standard© v6.5 and the inverse simulation technique was used to calculate heat input to the workpiece for each machining condition. As a general conclusion, an increase in cutting speed and feed rate leads to a decrease in heat input and temperature in the workpiece and thus, thermal distortion of the part.

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Abbreviations

%err av :

Average error

%err i :

Error in point i

Cpk :

Process capavility index

f :

Feed rate (mm/rev)

h :

Film coefficient (W m2 K)

HFL :

Heat flux (W/m2)

i :

Index of analysis point

l :

Hole depth (mm)

M :

Drilling torque (Nm)

n :

Rotation speed (r.p.m)

N :

Number of temporal points

q :

Surface heat flux (W/m2)

q ap :

Applied surface heat flux (W/m2)

q ap1 :

Surface heat flux applied in numerical model 1 (W/m2)

q ap2 :

Surface heat flux applied in numerical model 2 (W/m2)

q 1ch :

Surface heat flux to the chip from the primary heat generation zone (W/m2)

q 1wp :

Surface heat flux to the workpiece from the primary heat generation zone (W/m2)

q 3wp :

Surface heat flux to the workpiece from the tertiary heat generation zone (W/m2)

Q :

Heat (J)

Q 1ch :

Heat input to the chip from the primary heat generation zone (J)

Q 2ch :

Heat input to the chip from the secondary heat generation zone (J)

Q 2tl :

Heat input to the tool from the secondary heat generation zone (J)

Q 3tl :

Heat input to the tool from the tertiary heat generation zone (J)

Q Tot :

Total heat generated in the cutting process (J)

Q wp :

Heat input to the workpiece (J)

Q′ wp :

Heat input to the workpiece from the cutting zone (J)

Q″wp :

Heat input to the workpiece from the machined surface (J)

Q 1wp :

Heat input to the workpiece from the primary heat generation zone (J)

Q 3wp :

Heat input to the workpiece from the tertiary heat generation zone (J)

%Q :

Percentage of heat

%Q wp :

Percentage of heat that goes into the workpiece

t :

Time (s)

t c :

Cutting time (s)

T :

Temperature (°C)

T exp :

Experimental temperature (°C)

T num :

Numerical temperature (°C)

U :

Displacement (m)

V c :

Cutting velocity (m/min)

ε :

Emissivity

λ :

Thermal conductivity (W/mK)

λ′ :

Wavelenght (μm)

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Acknowledgments

The authors hereby thank the Basque Government for the financial support given through the projects CIC MARGUNE (code IE03-107) and TAF (IE05-148). The authors are grateful to Dr. Leire del Campo and Dr. Raul B. Pérez-Sáez for their help in emissivity determination of the samples.

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Authors and Affiliations

  1. IK4-Ikerlan S.Coop., 20500, Mondragon, Spain

    Unai Segurajauregui

  2. Faculty of Engineering, Mondragon University, 20500, Mondragon, Spain

    Unai Segurajauregui & Pedro José Arrazola

Authors
  1. Unai Segurajauregui
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  2. Pedro José Arrazola
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Correspondence to Pedro José Arrazola.

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Segurajauregui, U., Arrazola, P.J. Heat-flow determination through inverse identification in drilling of aluminium workpieces with MQL. Prod. Eng. Res. Devel. 9, 517–526 (2015). https://doi.org/10.1007/s11740-015-0631-x

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  • DOI: https://doi.org/10.1007/s11740-015-0631-x

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