OBRABOTKAMETALLOV Vol. 26 No. 1 2024 TECHNOLOGY Features of calculating the cutting temperature during high-speed milling of aluminum alloys without the use of cutting fl uid Dmitry Gubin 1, a, Anton Kisel’ 2, b, * 1 Omsk State Technical University, 11 Prospekt Mira, Omsk, 644050, Russian Federation 2 Kaliningrad State Technical University, 1 Sovetsky Prospekt, Kaliningrad, 236022, Russian Federation a https://orcid.org/0000-0003-1825-1310, gubin.89@list.ru; b https://orcid.org/0000-0002-8014-0550, kisel1988@mail.ru Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2024 vol. 26 no. 1 pp. 38–54 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2024-26.1-38-54 ART I CLE I NFO Article history: Received: 19 October 2023 Revised: 16 November 2023 Accepted: 22 January 2024 Available online: 15 March 2024 Keywords: Cutting temperature High-speed milling Aluminum alloy Homologous temperature Thermal imager Forecasting Specifi c work Yield strength ABSTRACT Introduction. The calculation of temperature during high-speed milling of aluminum alloys is of interest, since temperature can act as one of the main limiting factors in choosing rational milling modes. This is especially important when milling thin-walled products used in aircraft construction, since its high values can lead to local warping of the structure. It is not possible to control the temperature factor in production conditions, which makes it necessary to develop a mathematical model for calculating temperature. The purpose of the work is to develop a methodology for predicting the cutting temperature during high-speed milling of aluminum alloy workpieces for cutting conditions, in which it is not possible to use cutting fl uid. Methods. This paper presents experimental studies of the cutting temperature during high-speed milling of aluminum alloy workpieces without the use of cutting fl uid using non-contact temperature measurement methods. The results obtained were used to determine the coeffi cients substituted into formulas for calculating temperatures on the front and back surfaces of the cutting blade. Results and discussions. Based on the results of experimental tests and theoretical modeling, a temperature graph is drawn up. A comparison of experimental studies of milling of aluminum alloy D16T, with changing cutting conditions (the cutting speed changed) with theoretical data, gave a satisfactory result. The average relative error when comparing experimental data with theoretical one is 6.05 %. Based on experimental data, it can be concluded that the comparison of experimental data for measuring cutting temperatures is in satisfactory agreement with the proposed method of theoretical calculation of temperatures. The advantage of this technique is that it allows, without time-consuming and costly experimental studies, theoretically calculate (forecast) the temperatures on the front and back surfaces of the cutting blade, as well as the cutting temperature, for those narrow milling conditions, where eff ective heat removal from the cutting zone is impossible. It can also be used for milling aluminum alloys, the mechanical and thermophysical properties of which diff er. For citation: Gubin D.S., Kisel’ A.G. Features of calculating the cutting temperature during high-speed milling of aluminum alloys without the use of cutting fl uid. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2024, vol. 26, no. 1, pp. 38–54. DOI: 10.17212/1994-6309-2024-26.1-38-54. (In Russian). ______ * Corresponding author Kisel’ Anton G., Ph.D. (Engineering), Associate Professor Kaliningrad State Technical University, 1 Sovetsky Prospekt, 236022, Kaliningrad, Russian Federation Tel.: +7 999 458-08-25, e-mail: kisel1988@mail.ru Introduction The high-speed metal milling process is characterized by a high intensity of heat release. Determining the maximum temperature value and its distribution over the cutting surfaces of the tool is important, since it aff ects the choice of cutting modes, tool durability, and the quality of the machined surface of the part [1, 2, 3]. Thus, the maximum temperature values in determining the processing strategy act as one of the main limiting factors of cutting. The mechanism of heat generation during cutting is quite complex, however, three main factors can be distinguished: plastic deformation of the material, inhomogeneous shear and friction of the chips against the front surface of the tool, as well as friction of the back surface of the tool
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