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Title: Experimental investigation of the temperature fields generated during orthogonal machining

By: K.M.Vernaza Pena, J.J.Mason, T.C.Ovaert and Ming Li

Date: June 10-12, 2003.

Publication: NSF Workshop on research needs in thermal aspects of material removal processes, Stillwater, OK.

Abstract:
During the machining of metals, plastic deformation and friction lead to the generation of heat in the workpiece. Understanding the factors that influence the heat generation, flow and distribution in the tool and workpiece material near the cutting tool's edge is necessary. It is important to characterize the thermal field in the cutting zone in order to verify the numerical models of high speed machining and direct further advancement in this area. High speed HgCdTe infrared detectors are used to experimentally measure the temperature distribution at the surface of a workpiece during orthogonal cutting. From these temperature measurements, the heat generated in the primary shear zone and the friction zone can be examined and characterized. A modified split-Hopkinson bar apparatus has been developed to simulate orthogonal machining at speeds ranging between 10 to 100 m/s. In this work, a review of the temperature fields obtained during the orthogonal machining of 6061-T6 aluminium alloy and 1018 steel presented. The effects if rake angle and cutting speed on the heat generation are studied. it is observed that as the rake angle decreases, maximum temperatures increase and the primary shear zone in the workpiece contributes more to the temperature distrubution. It is also seen that as the cutting speed increases, maximum temperatures increase and a larger area of the workpiece is affected by the heat generation.