OBRABOTKAMETALLOV Vol. 27 No. 4 2025 145 TECHNOLOGY Investigation of the thermal loading during turning of a metal–composite system as a function of cutting speed, feed rate, and depth when machining a thin-walled 2 mm metal shell Nikolay Lubimyi a, Boris Chetverikov b, *, Sergey Klyuyev c, Nikolay Zagorodniy d, Andrey Polshin e, Ardalion Mal’tsev f, Mikhail Bytsenko g Belgorod State Technological University named after V.G. Shukhov, 46 Kostyukova St., Belgorod, 308012, Russian Federation a https://orcid.org/0000-0002-6131-3217, nslubim@bk.ru; b https://orcid.org/0000-0003-1801-6767, await_rescue@mail.ru; c https://orcid.org/0000-0002-1995-6139, klyuyev@yandex.ru; d https://orcid.org/0000-0002-2997-3282, n.zagorodnij@yandex.ru; e https://orcid.org/0000-0001-5809-4458, info@polshin.ru; f https://orcid.org/0000-0002-0878-3658, ardalion_bgtu@mail.ru; g https://orcid.org/0009-0004-2133-885X, b.michutka2005@gmail.com 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. 2025 vol. 27 no. 4 pp. 131–147 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2025-27.4-131-147 ART I CLE I NFO Article history: Received: 06 October 2025 Revised: 14 October 2025 Accepted: 07 November 2025 Available online: 15 December 2025 Keywords: Metal-composite systems Additive manufacturing Cutting temperature Metal-polymer Turning Funding This study was supported by grant No. 23-79-10022 from the Russian Science Foundation, https://rscf.ru/ project/23-79-10022/ Acknowledgements The study was performed using equipment from the High Technologies Center of BSTU named after V.G. Shukhov. ABSTRACT Introduction. This paper is devoted to the study of the thermal loading of the turning process for metal– composite systems (MCS) consisting of a thin-walled, additively manufactured metal shell and a metalpolymer fi ller. The purpose of this study is to investigate the infl uence of technological turning parameters on the temperature in the cutting zone of metal-composite systems (MCS) with a 2 mm thick metal shell and to determine the permissible machining conditions that prevent thermal degradation of the metal-polymer fi ller. Methodology. For experimental modeling of the MCS, a hardware-software complex was developed, including a replaceable metal sleeve made of 0.12C18Cr-10Ni-Ti steel, ferrochrome metal–polymer (TU 2257-002-48460567-00), three thermocouples with MAX6675 analog-to-digital converters, and a wireless data transmission module based on an ESP32. The temperature at the metal-metal-polymer interface was recorded in real time. The results were verifi ed using a non-contact method with a FLUKE Ti400 thermal imager (error of 3–5 °C). The experiment was conducted according to a full factorial design 23 + n 0 with variation of cutting speed V (m/min), feed rate S (mm/rev), and depth of cut t (mm), including central points for assessing the curvature of the response surface. Results and discussion. Based on the experimental data obtained for the 2 mm shell, a second-order regression model (2T3) was constructed, demonstrating high adequacy. Analysis of the model coeffi cients showed that the depth of cut t has the greatest infl uence on the temperature increase, followed by the feed rate S, while the cutting speed V has the least eff ect within the studied range. Using the model, response surfaces and contour maps were constructed, allowing visualization of safe machining regions that satisfy the constraint T ≤ 170 °C — the heat resistance limit of the metalpolymer. The obtained dependencies provide a basis for standardizing fi nishing turning parameters for tooling components with additively formed shells and metal-polymer fi llers. For citation: Lyubimyi N.S., Chetverikov B.S., Klyuev S.V., Zagorodniy N.A., Polshin A.A., Maltsev A.K., Bytsenko M.V. Investigation of the thermal loading during turning of a metal–composite system as a function of cutting speed, feed rate, and depth when machining a thin-walled 2 mm metal shell. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2025, vol. 27, no. 4, pp. 131–147. DOI: 10.17212/1994-6309-2025-27.4-131-147. (In Russian). ______ * Corresponding author Chetverikov Boris S., Ph.D. (Engineering), Associate Professor Belgorod State Technological University named after V.G. Shukhov, 46 Kostyukova St., 308012, Belgorod, Russian Federation Tel.: +7 951 134-32-43, e-mail: await_rescue@mail.ru References 1. Lubimyi N.S., Polshin A.A., Gerasimov M.D., Tikhonov A.A., Antsiferov S.I., Chetverikov B.S., Ryazantsev V.G., Brazhnik J., Ridvanov I. Justifi cation of the use of composite metal-metal-polymer parts for functional structures. Polymers, 2022, vol. 14 (2), p. 352. DOI: 10.3390/polym14020352.
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