2009 International Conference on Measuring Technology and Mechatronics Automation

Analysis and Study on Temperature Mathematical Model and Temperature Field in Milling Processing
X.L. Sui1
1,3

L.J. Jin2
2,4

J.T. Zhang3

X.P. Yang4

Department of Nuclear Power Engineering 1,3 Harbin Engineering University Harbin, Heilongjiang province, China 1 siuxiulin@sina.com 2jinlijuan830805@126.com

Contemporary Manufacturing Engineering and Cutter Exploitation Laboratory 2,4 Harbin university of science and technology Harbin, Heilongjiang province, China 3 zhangjiatai@hrbeu.edu.cn

AbstractAccording to theory of metal cutting and heat transfer, mathematical model of temperature field when work piece is milled by ball-milling cutter was established using moving heat source theory. Joint modeling method of work piece temperature field was studied in the environment of PRO / E and ALGOR. Three dimensional modeling of work piece was finished by PRO/E, and all-moving surface heat source's temperature field in milling process were dynamically simulated and had finite element analysis using ALGOR, and then distributed characteristic of the temperature field and rule that temperature on each point changed with time were got. This technology has laid a foundation for research of milling temperature's dynamic simulation and milling thermal deformation. Keywords-milling process; temperature field; moving heat source; finite element analysis;dynamic simulation insert

temperature's dynamic simulation and the milling thermal deformation. II. ESTABLISHMENT MATHEMATICAL MODEL OF
TEMPERATURE IN MILLING PROCESS

I.

INTRODUCTION

Cutting heat and it resulting cutting temperature are significant phenomenon in the process of cutting. Most energy which consumes in the cutting process transforms into heat energy, which causes work piece, chip and cutting tool's temperature rise. For a long time, the cutting temperature is calculated by the average temperature of cutting zone, although it can qualitatively reflect certain nature of cutting temperature, further study of cutting mechanism will be necessary to understand distribution of cutting temperature. With the development of computer technology, metal cuttings finite element simulation technology has been rapidly developed. The metal removal processing's finite element simulation has considered material attribute, cutting tool geometric condition, machining parameter (cutting velocity, feed rate, depth of cut) and so on. By physical simulation of metal removal cutting process, temperature field distribution of cutting tool, scrap and work piece may be known in advance the [1]. This article used large-scale finite element analysis software ALGOR to physically simulate the milling cutting process. Distributed characteristic of temperature field and the rule that temperature of each spot in work piece change along with the time were dynamic simulated when milling work piece was under all-moving surface heat source. This technology has laid the foundation for the research milling

In the metal removal process, main feature of its heat conduction is that heat source has certain shape and size, certain dynamic condition, and certain thermal output, but the boundary conditions are unknown. The traditional analytic method or numerical method solution is difficult to solve heat conduction of many cutting process, but heat source method is distinctive, especial for infinitely big heat conduction scope and heat source concentrating in the minimum infinitesimal volume, the heat source may get a simple explanation, and the computed result and the actual result is very similar. Therefore, this article utilizes heat source method to theoretically calculate temperature of cutting area. For the workpiece, the milling process heat source model can be seen as a moving limited surface heat resource. According to the instantaneous limited big surface heat temperature field can infer the moving limited big surface heat source temperature one. In infinitely great heat-transfer conduction, we suppose that heat-length is L, width is B (in

xoy plant) and its heat is Qm . The temperature rise of heat transient in any point M ( x, y , z ) after fever t seconds is
[2]:
2

=
erf

z Qm e 4 a erf 4c (4 a )1/ 2

x erf 4a

xB 4a

(1)

y erf 4a

yL 4a

capacity, cal ; is the density of heat conduction medium,

Where Qm is surface heat sources instantaneous calorific

g / cm3 ; c is the specific heat capacity of heat conduction medium, cal / g C ; a is the thermal diffusivity of heat

978-0-7695-3583-8/09 $25.00 2009 IEEE DOI 10.1109/ICMTMA.2009.195

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conduction medium, cm / s ; is anytime after instantaneous heat fever, s . Equation (1) is temperature field of instantaneous limited big surface heat sources. From (1) we can see that the limited big surface heat source is a three dimensional heat conduction question. From this model limited big surface heat source temperature field is derived. At the time that surface heat source begins to fever, it translates along the x axis with the speed v . From heat conduction differential equation we can get the micro unit (dx, dy, dz ) on cutting area, which makes temperature of
2

Equation (5) is the model of milling cutting area temperature rise. In (5) = t i , so d i = d .When i = 0 , so i as:
=
erf

= t , then = t ,so = 0 . Equation (5) can be written

d
z2 4 a

Qm 4c (4 a)1/ 2

t 0

e 1/ 2

erf

X + v X + v B erf 4a 4a

(6)

the point M ( x, y , z ) rise at d i . The temperature rise is:

d = erf
z Qm d i x v i x v i B e 4 a erf erf 1/ 2 4c (4 a ) 4a 4a
2

y erf 4a

yL 4a

(2)

y erf 4a

yL 4a

When analyzing temperature field of cutting area, the main consideration is temperature rise of each point nearby cutting area and the temperature with certain distance around heat source heading, therefore, the relative coordinates (moving coordinates) of the relative heat source was established[3]. Transformation relation of (2) coordinate is:

Mirror heat sources is considered. Because surface heat source in the milling process is on the surface of semiinfinite objects, mirror heat source after movement of plane mirror is entirely the same with the original heat source. The temperature of any point within objects should be superposition of true and mirror heat source, so the temperature of semi-infinite object is two times of temperature of an infinite object. Two times of the result of Eq.6 is what we want. Finally analytic form of work piece surface temperature field is obtained:
=
erf Qm 4c ( a)1/ 2
t 0

e 1/ 2

z2 4 a

erf

X + v erf 4a

X + v B 4a

(7)

x v i = x v(t ) = x vt + v

(3)

y erf 4a

yL 4a

Where x vt is position of X direction which is observed at M when i = t , that is, it is moving coordinate of x direction. Moving coordinate moves with heat source. So

The work piece surface temperature field can use (7) to calculate, from the equation we can see that surface temperature is relevant to many factors. It is not only relevant to heat acting time and position, but also to the cutting speed, cutting force, material properties of work piece and so on. III. TEMPERATURE FIELD FINITE ELEMENT SIMULATION
ANALYSIS

x v i = X + v
and then it is put into (2), so
d = erf
z Qm d i e 4 a erf 1/ 2 4c (4 a )
2

X + v erf 4a

X + v B 4a

(4)

y erf 4a

yL 4a

= t , temperature rise that moving surface heat source creates in cutting zone M can be
From integrated by (4).
=
erf Qm 4c (4 a)1/ 2
t 0

i = 0

to i

Finite element method, with variational principle as theoretical basis and digital computer, is widely used in the project field. The finite element method can simulate any kind of complex surface or surface boundary quite precisely, whose grid division is random, and can integrated deal with many kinds of boundary conditions. The solution precision will enhance unceasingly, and finally converges to the exact solution, as unit number increases, therefore, a satisfactory result can be obtained by the finite element method. This article uses large-scale general engineering simulation software ALGOR to analyze, according to the simulation process, has established the finite element analysis flow chart [4], as shown in Fig. 1. A. Finite element modeling The InCAD module in ALGOR provides correlation connection among all the major CAD software. This article uses PRO/E to establish geometric model. Because modeling

d i

1/ 2

z2 4 a

erf

X + v erf 4a

X + v B 4a

(5)

y erf 4a

yL 4a

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is difficult in ALGOR, PRO / E software which with a strong three-dimensional modeling features, can simplify structure as little as possible, guarantee that mathematical model is

The total heat per minute in cutting as follow:

qt can be calculated
(9)

qt = Fz v
Establish geometric model by Pro/E or CAD Model induction and grid generation Partial refinement and display grid Proprocessing Input material type,boundry condition and so on

Change parameter setting

Finite element method(FEM) simulation

Simulation process

End simulation calculation

Outputs and analysis simulation result

Reorganization and display of needed parameter

Total calories can be got from the calculation of the two equations above, 10 percent of calories should spread to work piece. There are thermal convection and radiation between the outer surface (except the bottom) of the work piece and the air (this article ignored thermal radiation and thermal convection), environment temperature of work piece is at 20C , milling direction is the right direction of X . Moving surface heat source which is loaded temperature is shown in Fig. 2.

Post-processing

Figure 1.

Finite element method (FEM) simulation process chart

identical with the real one, and greatly shorten time needed for modeling. Joint PRO / E with ALGOR modeling, we established a complete 3-D finite element model. Work piece 3 material is 45 steel, whose density is 7800kg / m , linear expansion coefficient is 10.1 10 / C , the thermal conductivity is 0.115 J / cm s C and specific heat is 465 J /(kg C ) when ambient temperature is 20C . The
6

Figure 2. After loading all-moving surface heat source model

overall size of the work piece is 80mm 50mm 20mm , and will be milled to a concave with R = 150mm by ballcutter. 3-D simulation of milling process is very complicated, currently the rotate contact problem between tool and work piece in the process simulation has not yet to be resolved. By simplifying milling heat source model to simulate temperature of the work piece, milling heat can be equivalent to surface heat. Action that surface heat works on work piece is equivalent to dynamic movement along the feed direction. Temperature of work piece at different time and temperature curve of any point changing rule are simulated and analyzed for different operating conditions. B. Boundary conditions setting The main cutting force in milling process is:
0.732 Fz = 2.54 aw a 0.84 d 0.988 v 0.55 f 0.003 z p

C. Result analysis Based on the milling conditions above, loading process will be divided into 14 load-steps. Fig. 3 is the temperature cloud atlas of work piece after two seconds cutting when the second load-step operation has finished. Fig. 4 is the temperature cloud atlas of work piece after five seconds cutting when the fifth load-step operation has finished. Fig. 5 is the temperature cloud atlas of work piece after eight seconds cutting when the eighth load-step operation has finished. Fig. 6 is the temperature cloud atlas of work piece after thirteen seconds cutting when the thirteenth load-step operation has finished. By analyzing the results of the model, we can clearly see temperature changes in the milling process.

(8)

Where

a p is milling depth, v is milling speed, f is feed

Figure 3. Movement result of second load step

rate, aw is milling width, d is tool diameter, z is cutter teeth. Simulated conditions are as follows: spindle speed n = 2400r / min , feed speed per tooth is 0.05mm / tooth , a p = 3mm , and aw = 10mm . Ballcutter material is high-speed steel, d teeth is three.

= 20mm , number of

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flux value of Y direction, Fig. 10 is the heat flux value of Z direction.

Figure 4. Movement result of fifth load step Figure 7. Heat flux total value

Figure 5. Movement result of eighth load step Figure 8. Heat flux total value of X direction

Figure 6. Movement result of thirteen load step

From Fig. 3, Fig. 4, Fig. 5 and Fig. 6 we can see that position surface heat source works changes with milling position changes in the process of milling. According to instructions of the column on the right of work pieces temperature cloud atlas, we can clearly observe the distribution of temperature of each location in processing. Thus, we will intuitively see changes that temperature of work piece takes dynamic changes with the milling process. From the results we can see the highest value of temperature on the surface of work piece rise with the growth of milling time. After 14 seconds of cutting, the maximum temperature of cutting area reaches 251.9C . This is because in the boundary hypothesis, we has not considered convection and the radiation between the work piece and environmental media, the quantity of heat only passes from the temperature high part to the temperature low part, therefore the maximum temperature elevates by the form of accumulation. Heat flux value can be inquired the in the result analysis. Fig. 7 is the total number of the heat flux value of the result. Fig. 8 is the heat flux value of X direction, Fig. 9 is the heat

Figure 9. Heat flux total value of Y direction

Figure 10. Heat flux total value of Z direction

From Fig. 7 we can see that the heat flux total maximum 2 value is 0.351J / mm s , heat flux value is maximum in the milling area which is loaded heat source. The farther to the heat source, the smaller the heat flux value is smaller. And we can also observe from the chart that the heat flux vector direction is along the isothermal surface normal, and directs temperature decreasing direction, which agrees well

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with the theory [5]. From Fig. 8, 9, 10 heat flux's value result we can see that flux value is the highest along the X direction which is the cutting tool direction of feeding, and the 2 maximum value is 0.204 J / mm s , which explains that the heat transfer speed of surface heat source is quicker along the X direction; Along the Y direction heat flux's value 2 maximum value is 0.186 J / mm s , but along the Z direction heat flux's maximum value is 2 only 0.002 J / mm s , which explains that the heat transfer speed is very small along the Z direction, thus we may believe that when ball milling cutter mills surface, cutting heat only affects temperature rise of very thin material nearby work piece surface layer, heat transfer speed along the direction vertical the processing surface is very slow, at processed surface, the temperature achieves highest, and the farther away from the surface layer, the temperature rises is smaller. Fig. 11 is the node number 2471, 2815 and 3156 temperatures change course on the work piece surface along with the time.

processing situation. The work piece surface's temperature maximum elevates unceasingly along with the milling time's extension; when ball milling cutter mills surface, cutting heat only affects the work piece surface layer nearby the very thin that part of material temperature rising; the temperature value of work piece surface's node achieve the maximum when all-moving surface heat source passes through it, then the temperature begins to drop, the drop speed is smaller than the rise speed, temperature of each node shows an increasing tendency. IV. CONCLUSION This article used moving heat source method to establish the work piece temperature mathematical model in the milling process, this model makes the known heat source as the known boundary condition to load, and thus extracts the distribution of the temperature field, this model could quietly direct-viewing reflect the heat conduction process in milling temperature field. Using large-scale general engineering simulation software ALGOR to simulate the work piece temperature field along with the time tendency change situation in the ball milling cutter milling surface process, obtained the work piece temperature field distributed characteristic, the work piece temperature field heat flux value chart and the work piece surface each temperature along with the time change rule under all-moving surface heat source function, provide the theory basis for the work piece heating distorted working accuracy error model establishment in the hypothesized milling physical simulation system. REFERENCES
[1] H. Meng, J. Zhao, and S. Y. Wang, Finite Element Analysis of Temperature Field in High-speed Cutting, Tool Engineering, vol. 39, no. 4, 2005, pp.21~23 G. J. Liu, G. Y. Tan, and G. H. Li, Research on mathematical model of temperature field for milling insert with 3D complex groove, Journal of Heilongjiang Institute of Technology (Natural Sciences Edition), vol. 18, no. 1, 2004, pp.1-4. Y. Zhou, X.C. Liang, and B. Chen, Calculations on Temperature Field for Super High-speed Milling and its Applications, China Mechanical Engineering, vol. 14, no. 13, 2003, pp.1158~1159. Richard. Y, chiou, Lin Lu, Jim S. J. Chen and Mark T. Nrth, Investigation of dry machining with embedded heat pipe cooling by finite element analysis and experiments, The International Journal of Advanced Manufacturing Technology, vol. 31, no. 9~10, 2007, pp.905~914, doi:10.1007/s00170-005-0266-8. Yu. B. Belousov, Evaluation of the concentration of a surface heat source with normal distribution of thermal power, Welding International,vol.17,no.1,2003,pp.53~56, doi:10.1533/wint.2003.3080. H. F. Wang, L.T. Wang, and G. S. Zhang, Research on Heat Source and Temperature Field Model in NC Milling Process, Group Technology & Production Modernization, vol.25, no.1, 2008, pp.31~35.

Figure 11. Superficial node temperature result

We can see from the chart that the superficial node temperature value achieves the maximum when the surface heat source passes through it, thus it may be known the nearer away from the heat source, and the temperature is higher. The speed of the node temperature rises quickly during the heat source passing process, then the temperature drops, the dropping speed is smaller than the rising speed. Because distribution is considering as triangle when heat source is loaded, the milling processing is intermittent, when a ball milling cutter just cuts into the work piece, it produces a little heat, and then its heat source intensity is small; its heat source intensity is maximum when cutting out, and out of work piece the heat source strength is zero, therefore the heat source intensity can be considered according to the triangle distributed situation [6]. We can see temperature of each node shows an increasing tendency from the chart, because temperature is elevated gradually by the form of accumulating. From the above ALGOR simulation's result we can see, finite element model using the motion heat source method can well simulate the temperature field distribution of the work piece under milling condition, match to the actual

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[5]

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