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. 2015 Jan 12;15(1):1274-91.
doi: 10.3390/s150101274.

Thermocouple and infrared sensor-based measurement of temperature distribution in metal cutting

Abdil Kus  1 , Yahya Isik  2 , M Cemal Cakir  3 , Salih Coşkun  4 , Kadir Özdemir  5
Affiliations

Thermocouple and infrared sensor-based measurement of temperature distribution in metal cutting

Abdil Kus et al. Sensors (Basel). .

Abstract

In metal cutting, the magnitude of the temperature at the tool-chip interface is a function of the cutting parameters. This temperature directly affects production; therefore, increased research on the role of cutting temperatures can lead to improved machining operations. In this study, tool temperature was estimated by simultaneous temperature measurement employing both a K-type thermocouple and an infrared radiation (IR) pyrometer to measure the tool-chip interface temperature. Due to the complexity of the machining processes, the integration of different measuring techniques was necessary in order to obtain consistent temperature data. The thermal analysis results were compared via the ANSYS finite element method. Experiments were carried out in dry machining using workpiece material of AISI 4140 alloy steel that was heat treated by an induction process to a hardness of 50 HRC. A PVD TiAlN-TiN-coated WNVG 080404-IC907 carbide insert was used during the turning process. The results showed that with increasing cutting speed, feed rate and depth of cut, the tool temperature increased; the cutting speed was found to be the most effective parameter in assessing the temperature rise. The heat distribution of the cutting tool, tool-chip interface and workpiece provided effective and useful data for the optimization of selected cutting parameters during orthogonal machining.

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Figures

Figure 1.
Figure 1.
The balance of heat generation and heat dissipation in metal cutting [23].
Figure 2.
Figure 2.
Co-temperature curves [24].
Figure 3.
Figure 3.
Schematic view of the experimental setup.
Figure 4.
Figure 4.
Block diagram of an IR pyrometer.
Figure 5.
Figure 5.
Emissivity range of the IR pyrometer.
Figure 6.
Figure 6.
K-Type thermocouple display.
Figure 7.
Figure 7.
Position of thermocouple.
Figure 8.
Figure 8.
Mounting of thermocouple onto the tool holder.
Figure 9.
Figure 9.
Thermocouple and IR pyrometer connections onto the lathe.
Figure 10.
Figure 10.
Change of tool temperature during the cutting process, depending on the time.
Figure 11.
Figure 11.
The influence of cutting speed and feed rate on temperatures.
Figure 12.
Figure 12.
The influence of feed rate and cutting speed on tool-chip interface temperature.
Figure 13.
Figure 13.
Chips form at different tool-chip interface temperatures and cutting speeds.
Figure 14.
Figure 14.
Boundary conditions.
Figure 15.
Figure 15.
Temperature distribution on the cutting insert.
Figure 16.
Figure 16.
Temperature distribution on the path from the tool-chip interface.
Figure 17.
Figure 17.
Temperature probe values for some locations.
See this image and copyright information in PMC

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