Beruflich Dokumente
Kultur Dokumente
of Mechanical Engineering, Vishwakarma Institute of Information Technology, Kondhwa (Bk.) Pune, M.S. India
Abstract
In modern industry, the trend towards using dry and high speed machining has caused much greater heat dissipation in the
chip formation zone and for this reason thermal phenomena play a key role in tool wear and machinability of the materials.
For the improvement of cutting performance, the knowledge of temperature at the tool-work interface with good accuracy is
essential. In this paper, calibration set-up was designed and developed in order to establish a relationship between obtained
e.m.f. during machining and the cutting temperature. Also, the most simplest and economical technique of temperature
measurement i.e. tool-work thermocouple set-up was developed for the measurement of the cutting temperature in machining.
The performance of the setup is evaluated for the different material like EN19, EN31, mild steel, SS 304 and SAE 8620. The
results obtained experimentally confirmed that the set-up is having
better
accuracy
and
good
repeatability.
Regression analysis is used for establishing the relationship between temperature and the generated voltage.
Machining
tests are carried out for SAE 8620 material for various cutting speed and feed using uncoated tungsten carbide tool. Cutting
temperatures are predicted.
Keywords: machining, tool-work thermocouple, tool wear, cutting temperature.
INTRODUCTION
WORKING PRINCIPLE
In manufacturing process, temperature has critical influence
on machining. It accelerates tool wear, shortening tool life. It causes
the thermal deformation of the work-piece, cutting tool and machine
tool, which degrades the machining accuracy; it affects the
subsurface layers of machined parts through phase transformation,
thermally induced residual stresses an increase in thermally
activated defects[1]. Abhang et al. [2] measured the tool-chip
interface temperature experimentally during turning of EN-31 steel
alloy with tungsten carbide inserts using a tool-work thermocouple
technique. Grzesik [4] dealt with experimental investigation into the
different factors which Influence the temperature which occur
at the coating/substratechip interface during machining of
medium carbon steel (AISI 1045) and an austenitic stainless steel
(AISI304). O'Sullivan et al. [6] demonstrated the use of embedded
thermocouples (in the work-piece) and the infrared thermal camera
to monitor the temperature during the process. To reduce
these defects, we developed a calibration setup on the basis of
Seebeck effect with the help of k-type thermocouple and
microcontroller. This setup helped us during calibration, resulted in
measuring the temperature during machining.
*Corresponding Author
Srihari Prasad A
Department of Mechanical Engineering, K.L.University, Vaddeswaram, Guntur,
A.P., 522502., India
Email: srihari.anne@gmail.com
16
Table 1. Elemental composition of SAE 8620
Carbon%
Mn.% Cr%
0.18
0.70
0.7
0.6
0.25
0.20
Calibration setup
Calibration set-up is developed in order to establish the
relationship between the e.m.f. produced and cutting temperature
during machining. In calibration set-up, tool-work thermocouple
junction is constructed using a long continuous chip of different workmaterial and fresh tungsten carbide inserts used in actual machining
operation. Electric air heater is used to as a heating element for the
work-tool junction and it simulates the thermal performance
phenomena in machining and raised the temperature at the chip-tool
interface. Work-tool material and the thermocouple wire are heated
directly as they are in contact with the electric heater. A standard
alumel- chromel thermocouple wire is mounted at the junction of chip
and insert. It has high temperature range of -200 C to 1350C. It
has better oxidation resistance. Type-K sensors are recommended
for use in oxidizing or completely inert environments.
a)
b)
Fig 3. Calibration set-up a) Front view b) top view
Fig1. Principle of work tool thermocouple
17
2) After maintaining the proper contact, one end of the copper wire is
connected to the tool and chip material and other end was connected
to the milli-voltmeter terminals. Then electric air heater was brought
in contact with the junction point for heating the junction point.
3) A standard alumel-chromel thermocouple wire was mounted at the
junction of chip and insert. And it is connected to the temperature
indicator calibrated for the Type-K thermocouple wire.
i.
ii. Microcontroller
Microcontroller is the heart of the system that is controlling all
the processes. The controller PIC 18f4620 is used due to its
numerous advantages such as huge memory size, built in ADC, can
source high current, more power handling capacity, DIP package,
low cost etc.
iii. Display
The LCD Display is used to display the temperature of the job
according to the inputs of the controller. The display 16x2 is used
due to high range display and clear visibility and low cost.
iv. Data Storage
The data storage element can be a USB device or a memory
card interface for storing data. This storage is very useful for keeping
the track of the system temperature. This track can be used for
future studies, analysis, and to keep record of
temperature according to time n date.
v. Real Time Clock
Real time clock is used to store data with respect time n date.
RTC DS1307 is used for this purpose which is
interfaced with the microcontroller.
The
4) After this, whole assembly was kept in the container insulated with
glass wool in order to reduce heat losses and electric heater is
turned on and junction point was heated gradually up to
750 c and corresponding e.m.f. is recorded.
5) Graph of temperature v/s generated e.m.f. was plotted and
calibration constant is found out by using regression analysis.
RESULTS AND DISCUSSIONS
The objective of the experiment is to measure the
temperature during
machining
process.
So,
after
carrying
out
the experiment on the basis of Seebeck effect by
using calibration setup temperature for machining is calibrated and is
verified by using regression analysis.
Graphical representation
To find relationship between temperature and voltage, by
taking temperature on y-axis and voltage on x-axis. Different
materials were used during experiment to check validity, repeatability
and accuracy of the calibration setup.
The following graphs show temp.-voltage (m.v.) relationship for
different materials.
EN-19
EN-31.
Table 2 shows readings displayed by micro-controller. As
temperature increases voltage increases correspondingly and
TIME column represents exact time when temp and voltages are
measured.
EXPERIMENTAL PROCEDURE
1) First, work-piece chip and tool material to be calibrated were
clamped with the help of clamping assembly in the set- up. While
clamping, care was taken to ensure the perfect contact between the
work-tool materials because improper contact can result in the erratic
readings.
18
SAE-8620
Table 3. Equations of lines for respective materials
SR. NO.
MATERIAL
EQUATION OF LINE
EN-19
Y=353.94X+94.15
EN-31
Y=174.52X+23.91
SAE-8620
Y=9.486X+20.63
Mild steel
Y=287.43X+11.2
Stainless steel
Y=10X+30
Mild steel
CONCLUSION
Regression analysis
From the graph, different value of voltage and corresponding
temperatures are obtained.In this way, graphical relationship of few
materials was obtained. During graphical representation equations
for respective lines were also obtained. it was
verified by using actual mathematical formulation for regression
analysis in statistics.
Formula for regression is
y = m.x + n.c . . . . . .(1)
xy = m.x2 + cx. . . . . .(2)
Here, y is taken as temperature value. whereas, x is taken as
voltage value. And n is no. of readings taken.
19