Studies on high-efficiency and high-precision orthogonal turn-milling-The effects of relative cutting speed and tool axis offset on tool flank temperature

• Published in: Precision engineering Vol. 66; pp. 180 - 187
• Main Authors: Shimanuki, Koji, Hosokawa, Akira, Koyano, Tomohiro, Furumoto, Tatsuaki, Hashimoto, Yohei
• Format: Journal Article
• Language: English
• Published: Elsevier Inc 01.11.2020
• Subjects: 3D-CAD analysis; Cutting temperature; Tool axis offset; Turn-milling; Two-color pyrometer; Undeformed chip; Tool axis offset; Two-color pyrometer; 3D-CAD analysis; Cutting temperature; Undeformed chip; Turn-milling
• ISSN: 0141-6359; 1873-2372
• DOI: 10.1016/j.precisioneng.2020.06.013

The cutting-edge temperature on the flank face in dry turn-milling of medium carbon steel (ISO C45) is measured using a two-color pyrometer with an optical fiber. In turn-milling, undeformed chip geometry is complex due to its dependence on several factors including diameter of the cutting tool, number of tooth, diameter of the workpiece, tool-work revolution speed ratio, depth of cut, feed per tooth, tool axis offset, and the cutting distance. In this study, the undeformed chip is analyzed and visualized by the 3D-CAD system, and the effects of the cutting parameters in turn-milling, especially relative cutting speed and tool axis offset on tool flank temperature, are investigated. It is interesting that the relative cutting speed does not significantly affect the tool flank temperature, where it increases by approximately 20 °C at most when relative cutting speed increases from 124 m/min to 217 m/min. In addition, tool flank temperature varies by approximately 40 °C when the tool axis offset is changed from 0 mm to 9.2 mm due to the change in the undeformed chip geometry. •Two-color pyrometer with an optical fiber makes it possible to measure the cutting tool temperature in turn-milling, where both workpiece and cutting tool rotate simultaneously.•The tool flank temperature increases with the increase of relative cutting speed, but the relative cutting speed gives less effect on the cooling characteristics of the cutting tool.•Secondary cut occurs when the cutting distance is approximately the cutting tool diameter, where a part of already machined surface is cut again by the back half of the cutter.•The effect of tool axis offset on the tool flank temperature is relatively small because the cutting time per tooth increases while the average cross-sectional cutting area simultaneously decreases with the tool axis offset.