Model-based Determination of Heat Partitioning in Industry Relevant Dry Cutting Processes

• Applicant: Dr.-Ing. Jens Sölter
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: since 2018
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 389472108

The main objective of the research proposal is to fundamentally describe the heat partition to the workpiece for industry relevant dry cutting processes. For this purpose the relevant machining parameters and the thermal conductivity of the workpiece material will be combined to dimensionless quantities. During the first project phase heat partitioning models have been successfully developed and validated for quasi orthogonal cutting and for surface milling. The resulting heat partitioning diagram provides the fraction of heat generated in the primary shear zone dissipating into the workpiece as a function of two dimensionless parameters. These parameters take into account the influence of cutting speed, feed speed, uncut chip thickness, shear angle as well as a determined process-dependent geometric constant and the thermal conductivity of the workpiece material. In the second project phase the applicability of the approach to external turning will be addressed. The different process kinematics have to be modelled by an additional heat partitioning model. Especially due to the analogy of the major cutting edge angle (reference plane) with the shear angle (cutting edge normal plane), the influence of the tool geometry on the heat partitioning has to be investigated. By systematic simulation-based studies it is sought to establish a process-independent functional relationship for heat partitioning in metal cutting processes.

• DFG Programme: Research Grants