Vol. 27 No. 3 2025 3 EDITORIAL COUNCIL EDITORIAL BOARD EDITOR-IN-CHIEF: Anatoliy A. Bataev, D.Sc. (Engineering), Professor, Rector, Novosibirsk State Technical University, Novosibirsk, Russian Federation DEPUTIES EDITOR-IN-CHIEF: Vladimir V. Ivancivsky, D.Sc. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Vadim Y. Skeeba, Ph.D. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Editor of the English translation: Elena A. Lozhkina, Ph.D. (Engineering), Department of Material Science in Mechanical Engineering, Novosibirsk State Technical University, Novosibirsk, Russian Federation The journal is issued since 1999 Publication frequency – 4 numbers a year Data on the journal are published in «Ulrich's Periodical Directory» Journal “Obrabotka Metallov” (“Metal Working and Material Science”) has been Indexed in Clarivate Analytics Services. Novosibirsk State Technical University, Prospekt K. Marksa, 20, Novosibirsk, 630073, Russia Tel.: +7 (383) 346-17-75 http://journals.nstu.ru/obrabotka_metallov E-mail: metal_working@mail.ru; metal_working@corp.nstu.ru Journal “Obrabotka Metallov – Metal Working and Material Science” is indexed in the world's largest abstracting bibliographic and scientometric databases Web of Science and Scopus. Journal “Obrabotka Metallov” (“Metal Working & Material Science”) has entered into an electronic licensing relationship with EBSCO Publishing, the world's leading aggregator of full text journals, magazines and eBooks. The full text of JOURNAL can be found in the EBSCOhost™ databases.
OBRABOTKAMETALLOV Vol. 27 No. 3 2025 4 EDITORIAL COUNCIL EDITORIAL COUNCIL CHAIRMAN: Nikolai V. Pustovoy, D.Sc. (Engineering), Professor, President, Novosibirsk State Technical University, Novosibirsk, Russian Federation MEMBERS: The Federative Republic of Brazil: Alberto Moreira Jorge Junior, Dr.-Ing., Full Professor; Federal University of São Carlos, São Carlos The Federal Republic of Germany: Moniko Greif, Dr.-Ing., Professor, Hochschule RheinMain University of Applied Sciences, Russelsheim Florian Nürnberger, Dr.-Ing., Chief Engineer and Head of the Department “Technology of Materials”, Leibniz Universität Hannover, Garbsen; Thomas Hassel, Dr.-Ing., Head of Underwater Technology Center Hanover, Leibniz Universität Hannover, Garbsen The Spain: Andrey L. Chuvilin, Ph.D. (Physics and Mathematics), Ikerbasque Research Professor, Head of Electron Microscopy Laboratory “CIC nanoGUNE”, San Sebastian The Republic of Belarus: Fyodor I. Panteleenko, D.Sc. (Engineering), Professor, First Vice-Rector, Corresponding Member of National Academy of Sciences of Belarus, Belarusian National Technical University, Minsk The Russian Federation: Vladimir G. Atapin, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Victor P. Balkov, Deputy general director, Research and Development Tooling Institute “VNIIINSTRUMENT”, Moscow; Vladimir A. Bataev, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Vladimir G. Burov, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Aleksandr N. Korotkov, D.Sc. (Engineering), Professor, Kuzbass State Technical University, Kemerovo; Dmitry V. Lobanov, D.Sc. (Engineering), Associate Professor, I.N. Ulianov Chuvash State University, Cheboksary; Aleksey V. Makarov, D.Sc. (Engineering), Corresponding Member of RAS, Head of division, Head of laboratory (Laboratory of Mechanical Properties) M.N. Miheev Institute of Metal Physics, Russian Academy of Sciences (Ural Branch), Yekaterinburg; Aleksandr G. Ovcharenko, D.Sc. (Engineering), Professor, Biysk Technological Institute, Biysk; Yuriy N. Saraev, D.Sc. (Engineering), Professor, V.P. Larionov Institute of the Physical-Technical Problems of the North of the Siberian Branch of the RAS, Yakutsk; Alexander S. Yanyushkin, D.Sc. (Engineering), Professor, I.N. Ulianov Chuvash State University, Cheboksary
Vol. 27 No. 3 2025 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Kondratiev V.V., Gozbenko V.E., Kononenko R.V., Konstantinova M.V., Guseva E.A. Determination of the main parameters of resistance spot welding of Al-5 Mg aluminum alloy..................................................................................... 6 Gvindjiliya V.E., Fominov E.V., Marchenko A.A., Lavrenova T.V., Debeeva S.A. Infl uence of cutting speed on pulse changes in the temperature of the front cutter surface during turning of heat-resistant steel 0.17 C-Cr-Ni-0.6 Mo-V................................................................................................................................................................ 23 Karelin R.D., Komarov V.S., Cherkasov V.V., OsokinA.A., Sergienko K.V., Yusupov V.S., Andreev V.A. Production of rods and sheets from TiNiHf alloy with high-temperature shape memory eff ect by longitudinal rolling and rotary forging methods.................................................................................................................................................................... 37 EQUIPMENT. INSTRUMENTS Zakovorotny V.L., Gvindjiliya V.E., Kislov K.V. Information properties of vibroacoustic emission in diagnostic systems for cutting tool wear................................................................................................................................................ 50 Zhukov A.S., Ardashev D.V., Batuev V.V., Kulygin V.L., Schuleshko E.I. Modal analysis of various grinding wheel types for the evaluation of their integral elastic parameters...................................................................................... 71 Nishandar S.V., Pise A.T., Bagade P.M. Numerical and experimental investigation of heat transfer augmentation in roughened pipes................................................................................................................................................................ 87 Nosenko V.A., Rivas Perez D.E., Alexandrov A.A., Sarazov A.V. The eff ect of the grinding method on the grain shape coeffi cient of black silicon carbide....................................................................................................................................... 108 MATERIAL SCIENCE Karlina Yu.I., Konyukhov V.Yu., Oparina T.A. Investigation of the process of surface decarburization of steel 20 after cementation and heat treatment.................................................................................................................................. 122 Kovalevskaya Z.G., Liu Y. Eff ect of heat treatment on the structure and properties of high-entropy alloy AlCoCrFeNiNb0.25............................................................................................................................................................. 137 Sirota V.V., Prokhorenkov D.S., Churikov A.S., Podgorny D.S., Alfi mova N.I., Konnov A.V. Corrosion properties of coatings produced from self-fl uxing powders by the detonation spraying method............................................................ 151 Filippov A.V., Shamarin N.N., Tarasov S.Yu., Semenchyuk N.A. The infl uence of structural state on the mechanical and tribological properties of Cu-Al-Si-Mn bronze............................................................................................................. 166 Waheed F., Qayoom A., Shirazi M.F. Fabrication, characterization and performance evaluation of zinc oxide doped nanographite material as a humidity sensor......................................................................................................................... 183 Dolgova S.V., Malikov A.G., Golyshev A.A., Nikulina A.A. Features of the structure of gradient layers «steel - Inconel - steel», obtained by laser direct metal deposition.................................................................................................. 205 Burkov A.A., Dvornik M.A., Kulik M.A., Bytsura A.Yu. The infl uence of tungsten carbide particle size on the characteristics of metalloceramic WC/Fe-Ni-Al coatings.................................................................................................... 221 Patil S., Chinchanikar S. Investigation on the mechanical properties of stir-cast Al7075-T6-based nanocomposites with microstructural and fractographic surface analysis...................................................................................................... 236 EDITORIALMATERIALS 252 FOUNDERS MATERIALS 263 CONTENTS
OBRABOTKAMETALLOV Vol. 27 No. 3 2025 technology Influence of cutting speed on pulse changes in the temperature of the front cutter surface during turning of heat-resistant steel 0.17 C-Cr-Ni-0.6 Mo-V Valery Gvindjiliya a, *, Evgeny Fominov b, Andrey Marchenko c, Tatiana Lavrenova d, Svetlana Debeeva e Don State Technical University, 1 Gagarin square, Rostov-on-Don, 344000, Russian Federation a https://orcid.org/0000-0003-1066-4604, vvgvindjiliya@donstu.ru; b https://orcid.org/0000-0002-0165-7536, fominoff83@mail.ru; с https://orcid.org/0000-0003-4028-6712, tobago13@yandex.ru; d https://orcid.org/0000-0002-8283-7730, bys_ka87@mail.ru; e https://orcid.org/0000-0002-2796-2424, sve_tchk@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. 2025 vol. 27 no. 3 pp. 23–36 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2025-27.3-23-36 ART I CLE I NFO Article history: Received: 13 April 2025 Revised: 25 April 2025 Accepted: 21 May 2025 Available online: 15 September 2025 Keywords: Longitudinal turning Heat-resistant steel Kinematic disturbance Front surface temperature ABSTRACT Introduction. This paper is devoted to the evaluation of the influence of periodic fluctuations of machining mode parameters on the change of the maximum temperature of the front surface of the cutter. Subject of research. Fluctuations of cutting mode parameters are considered as deviations of their values relative to the nominal ones, resulting in periodic changes in the cross-sectional area of the cut layer and the interaction conditions between the chip and the tool’s front surface, which affect temperature changes in the cutting zone. The purpose of this work is to evaluate the influence of periodic fluctuations of machining mode parameters at different cutting speeds on the variation of the maximum temperature of the cutting tool’s front surface during turning of heat-resistant steel 0.17 C-Cr-Ni-0.6 Mo-V on a long-life machine without cooling. Method and methodology. The finishing longitudinal turning process of heat-resistant steel 0.17 C-Cr-Ni-0.6 Mo-V on a long-life machine without cooling was investigated. During machining, tool vibrations were measured along three coordinate axes while varying the cutting speed at constant depth of cut and feed. Using digital simulation modeling based on input data obtained from in-situ experiments, the moments in the system dynamics when each cutting mode parameter reaches extreme values due to fluctuations were identified. Deviations of the maximum design temperature from the corresponding nominal value were then determined. Results and discussion. It is established that variations in machining speed change the factors destabilizing the thermal state: at low speeds, the main sources of temperature deviations in the investigated cutting system are moments when extreme values of cutting depth and speed are reached; at higher speeds, fluctuations of cutting depth and feed have the greatest effect. It is revealed that when machining parameters reach extreme values, instantaneous temperature generally increases, and cutting speeds at which such deviations are minimal are identified. For citation: Gvindjiliya V.E., Fominov E.V., Marchenko A.A., Lavrenova T.V., Debeeva S.A. Influence of cutting speed on pulse changes in the temperature of the front cutter surface during turning of heat-resistant steel 0.17 C-Cr-Ni-0.6 Mo-V. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2025, vol. 27, no. 3, pp. 23–36. DOI: 10.17212/1994-6309-2025-27.3- 23-36. (In Russian). ______ * Corresponding author Gvindjiliya Valery E., Ph.D. (Engineering), Senior Lecturer Don State Technical University, 1 Gagarin square, 344000, Rostov-on-Don, Russian Federation Tel.: +7 918 583-23-33, e-mail: vvgvindjiliya@donstu.ru Introduction One of the main factors determining the wear resistance of cutting tools is the temperature in the machining zone. Over the past decades, a significant number of scientific studies have been devoted to the assessment and prediction of maximum temperatures on the surface of cutting tools. Experimental methods for determining this parameter by contact measurement and analysis of heat emission have been proposed [1–3], and various analytical dependencies for predicting temperature have been presented [4–7]. Another relevant area of research is the assessment of the influence of process conditions on the temperature in
OBRABOTKAMETALLOV technology Vol. 27 No. 3 2025 the cutting zone. Most of the works presented in this area are devoted to studying changes in the average temperature when one of the cutting mode parameters varies, but the effect of vibrations generated by the system itself at certain processing modes on the nature of heat dissipation in the contact zone has not been analyzed [8–12]. At the same time, studies show that cutting tool vibrations and the temperature in the cutting zone are highly correlated. For example, Songyuan Li et al. show the results of the influence of tool vibrations on temperature for different stages of tool wear [13]. Qiu Yu et al. also note the significant influence of cutting modes and tool vibrations on the thermal state in the processing zone, while noting that this relationship is characterized by nonlinear properties and depends on the operating parameters of the cutting system [14]. The temperature in the cutting zone reaches its maximum value at the end boundary of the secondary plastic deformation (SPD) zone on the tool rake face. The “tool rake face-chip” interface is a heavily loaded tribological system, in which the cutting edge of the tool heats up as a result of viscous dissipation of friction energy in the surface deformable microvolume of the chip. By applying hydrodynamic analogies to the assessment of deformation processes in the SPD layer, A.V. Chichinadze and K.G. Shuchev obtained an analytical dependence describing the temperature distribution along the rake face and allowing the maximum temperature at this edge to be determined [15]. The parameters of the volumetric heat source in the chip are determined by the specified cutting modes. At the same time, as a result of various vibration disturbances in the cutting system, one or more of the initially specified processing parameters (speed, feed, cutting depth) periodically deviate from their nominal values, changing the set of tribodeformation indicators that determine the maximum instantaneous contact temperature. As a result of the variable nature of the heat sources on the rake face, there will be periodically repeating impulsive changes in the instantaneous temperature associated with mechanical vibrations of the machine’s actuators. The specific deviation of this indicator from the nominal value will be determined by a set of values that each of the processing mode parameters takes at the moment of fluctuations. An increase in the amplitude of the variable temperature component leads to an increase in the temperature gradient in the cutting wedge as a whole and to an increase in undesirable heat flows. Temperature fluctuations in areas adjacent to the zone of primary plastic deformation change the characteristics of the material being processed and affect the cutting forces. The unstable thermal state of the cutting zone and the variable nature of the thermal load on the cutter surfaces cause intensification of oxidative and diffusion wear of the working edges of the tool [17–19]. At the same time, thermodynamic processes on the tool face largely determine the thermal state and wear processes on its flank face [20, 21]. Negative temperature effects are particularly acute during dry cutting of heat-resistant materials with low thermal conductivity [22–24]. The use of equipment with a long service life is an additional factor that increases tool vibrations and increases the temperature in the processing area. Such equipment is prone to significant kinematic disturbances originating from the feed drives and the main drive during machining. The purpose of this work is to evaluate the influence of periodic fluctuations in processing parameters, induced at different cutting speeds, on changes in the maximum temperature of the cutter’s rake face when turning heat-resistant 0.17 C-Cr-Ni-0.6 Mo-V steel on a machine with a long service life without coolant. Methods Real-life tests were carried out in production conditions (Atommash factory, Volgodonsk) on a DIP-300 universal turning machine. External longitudinal turning of workpieces with a diameter of 109 mm and a length of 400 mm made of 0.17 C-Cr-Ni-0.6 Mo-V steel was performed using cemented carbide inserts (WC 79 %; TiC 15 %, Co 6 %) with the following cutting edge geometry: back rake angle γ = 6°, clearance angle α = 6°, major cutting edge angle φ = 95°, and nose radius r = 0.5 mm. Turning was performed at a feed rate of s = 0.198 mm/rev, a cutting depth of t = 0.5 mm, and a spindle speed of n = 630–1,000 rpm (cutting speed V = 215.5–343.6m/min). Theworkpieces were centered and pre-turned. To increase the rigidity of theworkpiece subsystem, a reinforced precision rotating tailstock BISON 8814-5 NC PRECISION 20/30 was used. Tool vibrations measured in the directions of its mobility were selected as the main information channels about the dynamics of the cutting process, as they have a greater impact on fluctuations in technological
OBRABOTKAMETALLOV Vol. 27 No. 3 2025 technology modes. To measure tool vibrations, a stand consisting of three A603C01 accelerometers, an LCard E20-10 analog-to-digital converter (ADC) with an input signal sampling frequency of up to 10 MHz, and a BTK-2-010 ICP converter for amplifying and proportionally converting vibration acceleration signals into alternating voltage with a frequency range of 0.1–50,000 Hz (Fig. 1) was used. The signal sampling frequency was 10 kHz per channel. Signals were recorded using L-Graph II software, and experimental data processing and identification of the parameters of the digital model of the cutting process were performed using Matlab and Simulink software. a b Fig. 1. General view of the equipment for the study: a – vibration accelerometers (1); b – continuous vibration monitoring system of the tool: ADC E20-10 (2) and ICP transducer VTK-2-010 (3) The dynamic cutting system model is represented as a set of three interconnected subsystems. The first subsystem controls the movement of the cutting tool relative to the workpiece, i.e., it sets the cutting parameters and the inertial-dissipative properties of the system. The second subsystem models the elastic deformations and cutting forces acting on the tool. The third subsystem implements a block for simulating uncontrolled disturbances, the source of which are kinematic disturbances from the machine’s drive system and spindle runout [25]. When modeling the dynamics of the machining process, the values of the cutting speed V, feed rate s, and cutting depth t were determined as follows: for each parameter, the value was determined by the sum of the value set by the control system (V0, s0, t0), deformation displacements H = {HX,HY,HZ}, mm, and deformation displacement rates η = dH/dτ = {ηX,ηY,ηZ}, mm/s, as well as vibration disturbances Δ = {ΔX,ΔY,ΔZ}, mm. Vibration disturbances are periodic functions of time and can be represented as: = ∆ = ∆ τ = ω τ ν τ = ∆ τ = ω ω τ ∑ ∑ 1 1 ( ) sin( ), ( ) / cos( ), k i n n n k i i n n n n A d d A (1) where An, ωn are the amplitudes and frequencies of the oscillators disturbing the movement of the tool in the directions of movement i = {X,Y,Z}, determined experimentally. The final representation of the cutting modes was modeled as follows: ( ) ∆ τ ∆ τ−τ = − η + ν = − η + ν τ = − + ∆ ∫ 0 0 0 ; ; , Z Z x X X Y Y V V s V d t t H (2)
OBRABOTKAMETALLOV technology Vol. 27 No. 3 2025 where τ0 =1/Ω is the time of one rotation of the part, s; Ω is the rotation frequency of the part, Hz; Vx is the feed speed, Vx = s0·Ω, mm/s. The maximum contact temperature on the rake face was calculated for each combination of V, s, and t values that they take at the moments of fluctuations due to tool vibrations using the Chichinadze-Shucheva analytical dependence [15]: ω ω = + + − ⋅ ⋅ − ⋅ ⋅ ⋅ × + π 3 2 01 02 1 1 1 1 2 2 2 2 2 2 2 2 1 3 1 1 2 2 1 1 2 exp C C C C C l l l l T k a k a k a rfc k a l k m V V V V k a V − λ × λ ⋅ + π ⋅ 1 2 1 1 1 2 2 , C m l a V (3) where ω01 is the maximum volumetric density of the heat source from friction forces in the tool body, W/m3; ω = − − 0 02 1 exp H H m m q kt T t h k T is the initial density of the heat source in the material being processed, W/m3; q 0 is the specific friction power for the front surface, W/m2; k 1, k2 are the heat absorption source localization coefficients for the tool and the material being processed, respectively, m–1; a 2 is the thermal conductivity coefficient of the workpiece, m²/s; λ1, λ 2 are the thermal conductivity coefficient of the solid alloy and the workpiece material, respectively, W/m·°C; Vc is the chip feed rate on the front surface, m/s; τk is the average tangential stresses on the front surface, Pa; Tm is the melting point of the workpiece material, oC; k is the temperature coefficient, oC; k = 7.143·10–4· T m; h is the average thickness of the plastically deformed layer in the chip, m; TH is the temperature difference within the plastically deformed layer, oC; l 1 is the length of the SPD zone on the rake face, m; α = λ 1 1 1 1 1 m A P , А1 is the tribocontact area on the SPD zone, m2; P 1 is the perimeter of tribocontact on the SPD zone, m; α1 is the heat transfer coefficient of the tool material, m2/°C. The average thickness of the SPD zone is determined by the empirical relationship [26]: τ = λ 1 2 . k m l h T (4) To account for the influence of cutting force variations during fluctuations on the values of parameters τk and h, the average shear stress on the rake face was determined as τk = FXY/Ak, Pa, where FXY is the resultant cutting force for the longitudinal (X) and radial (Y) directions, and Ak is the total contact area between the chip and the rake face, defined as Ak =2·l1·b. The values of the contact length l1 and the width of the cut layer b were determined using the methods [27] and [28], respectively. Results and Discussion The data on oscillatory accelerations recorded by vibration sensors were analyzed and processed. The oscillation velocity and displacement of the tool relative to the workpiece were calculated. Fig. 2 shows the vibration characteristics of the cutting process in the longitudinal direction, which is responsible for variations in the area of the cut layer. Based on the spectral characteristics of the data from the measuring system, the dominant frequency components of the system and kinematic disturbances were established.
OBRABOTKAMETALLOV Vol. 27 No. 3 2025 technology Vibration characteristics, as exemplified by the tool holder assembly, exhibit a broadband signal. Analysis of the low-frequency range shows that three main frequencies can be distinguished in the vibration spectrum of the tool holder assembly. The first of these coincides with the frequency of the spindle assembly vibrations. The others, including those in the mid-frequency range, are components of kinematic disturbances. Based on the data obtained, the dynamics of the cutting process were simulated, taking into account the influence of vibration disturbances (1) [29]. Examples of cutting force dynamics for different cutting speeds are shown in Fig. 3. The range includes both speeds used in full-scale experiments on the machine: V = 216 m/min, V = 270 m/min, V = 343 m/min, and intermediate values obtained by simulation digital modeling. Regarding the cutting process power indicator dynamics, the upper limit of the optimal workpiece spindle speed range will be values below the first frequency component of kinematic disturbances (12.5 Hz (Fig. 2)), i.e., n < 700 rpm or V < 252 m/min. Spindle speeds n = 800 rpm (V = 270 m/min) and n = 930 rpm (V = 318 m/min) can be used as processing parameters, provided that the part rotation frequency remains constant, since variations in the rotation frequency of the workpiece by 1 Hz can lead to a significant deterioration in the dynamics of the cutting process (Fig. 3). In this case, small variations in the cutting parameters in the quasi-stable parameter zone (V = 343 m/min) correspond to significant variations in cutting forces, exceeding the variations of similar parameters at V = 216 m/min and V = 270 m/min by 1.6 to 2 times. The results of modeling variations in three cutting parameters using the example of processing speed within the optimal range (216.5 m/min) and beyond it (343.6 m/min) in terms of minimizing variations in the cut-off layer are shown in Fig. 4, a, b. It is worth noting the effect of suppression of high-frequency components of disturbances from the spindle assembly and the establishment of natural vibrations of the cutting system at V = 343.6 m/min, while kinematic disturbances from the tool holder assembly continue to disturb the trajectory of the tool in the longitudinal direction, which leads to variations in the area of the cut-off layer. a b Fig. 2. Example of processed data for tool oscillatory velocity in the longitudinal direction: a – time-domain signal; b – amplitude spectrum of oscillatory velocity in mid-frequency and low-frequency range
OBRABOTKAMETALLOV technology Vol. 27 No. 3 2025 Fig. 3. Modeling of cutting forces along X, Y, Z directions for s = 0.198 rpm, t = 0.5 mm over the spindle speed range V = 216–343 m/min Periodic changes in the area of the cut-off layer due to fluctuations in cutting conditions (V, s, t) relative to their nominal values cause periodic variations in cutting forces, which lead to periodic changes in chip pressure on the tool rake face. In fact, there is a periodic restructuring of the functioning of the “chip-rake face” tribosystem, the characteristics of which directly affect the temperature change in the cutting zone. In this case, a complex relationship is formed between mechanical and thermodynamic processes, which is determined not only by the characteristics of the interacting subsystems of the mechanical part but also by tribophysical phenomena that affect the properties of the environment in the cutting zone. Although the formation of these relationships is caused by external disturbances originating from the mechanical systems of the machine tool, the thermodynamic state of the contact zone is more strongly influenced by the physical and mechanical properties of the tool and workpiece materials, which determine the characteristics of elastic-plastic deformation. Deformation processes at the points of contact between the chip and the front face of the tool are both a consequence of the dynamics of the cutting process and a source of new nonlinear transformations in the machining zone, including those affecting tool wear and the quality of the machined surface. This necessitates an analysis of the mutual influence of the mechanical and thermodynamic characteristics of the cutting process dynamics based on parameters that can be measured in the system. To evaluate the temperature change at the tool rake face due to variations in cutting modes and forces characteristic of each spindle speed, we will identify quasi-static instances in the system dynamics when the speed, feed, and cutting depth reach their extreme values as a result of fluctuations. For each of these time points, we will determine the values of the other two parameters of the machining modes and the values of the resultant cutting forces FXY at that moment (Table 1, 2, column 2–5). Based on the data obtained, the main tribological indicators (3) are calculated using Eq. 3, which determine the maximum temperature of the front edge Tmax, at the moments of extreme values of the parameters V, s, and t (Tables 1, 2, column 6–10). The deviations of the maximum surface temperature
OBRABOTKAMETALLOV Vol. 27 No. 3 2025 technology а b Fig.4. Fluctuations of technological modes: a – V = 216.5 m/min; b – V = 343.6 m/min Ta b l e 1 Variations of technological modes, cutting forces and main tribological parameters for V = 216.5 m/min Parameter state at the moment of fluctuation V, m/min s, mm/rev t, mm FXY, N l1, mm h, μm τк, MPa Ka Tmax, оС ∆T, оС AT, оС (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) nominal 216.5 0.198 0.5 228 0.24 23 508 2.005 1139.2 0 – V→max 217 0.234 0.51 257 0.28 25 471 1.998 1134.5 −4.7 26.8 V→min 216.2 0.173 0.48 230 0.21 24 619 2.013 1161.2 +22.1 s→max 216.8 0.242 0.49 271 0.29 27 498 1.998 1149.7 +10.6 10.6 s→min 216.3 0.157 0.47 218 0.19 21 576 2.703 1142.6 +3.4 t→max 216.8 0.225 0.53 247 0.28 24 460 1.998 1133.1 −6.1 35.9 t→min 216.3 0.176 0.46 235 0.20 25 651 2.014 1168.9 +29.8
OBRABOTKAMETALLOV technology Vol. 27 No. 3 2025 from the nominal value ∆T and the amplitude of its change at the moments of AT fluctuations are also presented (Table 1, 2, column 11–12). According to the simulation results, at n = 630 rpm, the greatest increase in instantaneous temperature occurs when the cutting depth reaches its minimum value. At the same time, at the moments of fluctuations, there are combinations of parameters V, s, and t, at which their complex values practically level out the change in instantaneous temperatures (at V → max; s → min). It should also be noted that, as a result of vibrations under these processing conditions, the maximum instantaneous temperature may decrease relative to the nominal value (at V → max; t → max). When the cutting speed is increased, negative temperature deviations at moments of fluctuation are less pronounced or cease altogether. Thus, when turning at a speed of V = 343.6 m/min, for any combination of cutting mode parameters, the instantaneous temperature changes only increase (Table 2, column 11). The amplitudes of temperature spikes generally increase with an increase in spindle speed, and the factors contributing to the generation of positive temperature spikes also change. If at V = 216.5 m/min the main sources of temperature spikes with maximum amplitude are the moments of reaching extreme values of the parameters t and V, then at higher speeds, fluctuations in cutting depth and feed rate have a significant effect. Thus, when turning at V = 343.6 m/min, fluctuations with heating of the tool surface by an additional 61–70 °C occur more frequently, which is due to significant variations in the area of the cut layer due to vibrations characteristic of this machining mode. Table 3 shows the amplitudes of periodic temperature changes for different spindle speeds n. The highest values of the AT parameter at each machining speed are underlined, thus highlighting the cutting mode parameters whose fluctuations contribute most to the instability of the thermal state of the cutting zone at each value of n. The investigated speed range has a pronounced local minimum corresponding to a speed of 270 m/ min, for which the lowest values of the AT parameter are achieved at all extreme values of the turning modes. Increasing the spindle speed above this value leads to a change in the nature of temperature spikes (sources V, t are replaced by s, t) and an increase in AT amplitudes. Ta b l e 2 Variations of technological modes, cutting forces and main tribological parameters for V = 343.6 m/min Parameter state at the moment of fluctuation V, m/min s, mm/rev t, mm FXY, N l1, mm h, μm τк, MPa Ka Tmax, оС ∆T, оС AT, оС (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) nominal 343.6 0.198 0.5 142 0.24 14 319 1.962 1092.2 0 – V→max 345.4 0.17 0.507 149 0.21 15 386 1.967 1117.9 +25.8 32.8 V→min 343.5 0.158 0.47 139 0.19 15 423 1.974 1124.9 +32.8 s→max 344.2 0.207 0.509 205 0.25 20 430 1.959 1152.8 +60.7 60.7 s→min 344.5 0.151 0.47 119 0.17 13 382 1.975 1101.3 +9.1 t→max 344.7 0.168 0.519 194 0.21 19 496 1.966 1162.5 +70.3 70.3 t→min 343.8 0.157 0.45 139 0.18 15 447 1.976 1132.6 +40.4 Ta b l e 3 Calculated amplitudes of periodic temperature variations ΔT at moments when parameters V, s, and t reach extreme values Cutting parameters Amplitude AT, оС 216.5 m/min 252 m/min 270 m/min 294 m/min 318 m/min 343.6 m/min V 26.8 31.1 17.8 21.2 24.8 32.8 s 14.1 18.1 12.5 36.1 42.5 60.8 t 35.9 43.2 26.4 41.6 51.4 70.3
OBRABOTKAMETALLOV Vol. 27 No. 3 2025 TEchNOLOgy Conclusion Based on the results of digital simulation modeling using data from real-life experiments, deviations of the contact temperature from the nominal value were determined for instances when one of the cutting parameters takes on an extreme value as a result of fluctuations. It was established that the combination of processing parameters at such moments generally leads to an instantaneous increase in the maximum temperature on the tool rake face, characterized by the concept of a thermal flash, but at the same time, for some combinations, a slight decrease in this indicator is possible. Within the range of parameters studied, the optimal cutting speed was identified, at which the output of all three processing parameters to extreme values leads to a minimal change in temperature on the rake face. It has also been established that this cutting speed is the boundary that divides the studied speed range into two intervals, differing in factors that destabilize the thermal state of the contact zone. When turning a workpiece at a speed below this limit, the greatest temperature deviations occur when the cutting depth and cutting speed reach extreme values. When the processing speed exceeds the optimal value, the main sources of contact temperature changes become the cutting depth and feed rate. Therefore, the factor limiting the productivity of the machining process in terms of minimizing temperature fluctuations is the variation in the area of the cut-off layer due to kinematic disturbances characteristic of the investigated cutting system at higher turning speeds. The research results presented in this paper can be used to select rational processing parameters, taking into account the kinematic disturbances of the machine tool support group and the thermodynamic state of the contact zone, which depends on their manifestations. The methodology allows evaluating and selecting technological parameters in which force fluctuations minimize possible impulse changes in the temperature of the tool rake face during dry turning. However, it is applicable only for operations that do not use coolant; in the case of the presented work, this was the operation of finishing turning a part of the “Connecting leg” type. The influence of coolant on pulsed heat release changes will be assessed in further studies. First and foremost, the presented methodology will be effective for machine tool fleets with medium and high degrees of wear, accelerating time-consuming tests to determine optimal operating modes when new tools are delivered. The use of temperature fluctuations caused by kinematic errors as an additional parameter for evaluating the optimality of cutting parameters in vibration monitoring and compensation systems can improve process stability and reduce the overall temperature in the cutting zone. Taking into account temperature changes calculated from the vibration activity signal of the tool is particularly relevant for metal-cutting machines with a long service life, which are characterized by significant periodic disturbances in the cutting system from the feed drives and the main drive. References 1. Komanduri R., Hou Z.B. Areview of the experimental techniques for the measurement of heat and temperatures generated in some manufacturing processes and tribology. Tribology International, 2001, vol. 34 (10), pp. 653–682. DOI: 10.1016/S0301-679X(01)00068-8. 2. Grzesik W. Experimental investigation of the cutting temperature when turning with coated indexable inserts. International Journal of Machine Tools and Manufacture, 1999, vol. 39 (3), pp. 355–369. DOI: 10.1016/S08906955(98)00044-3. 3. Sutter G., Faure L., MolinariA., Ranc N., PinaV.An experimental technique for the measurement of temperature fields for the orthogonal cutting in high speed machining. International Journal of Machine Tools and Manufacture, 2003, vol. 43 (7), pp. 671–678. DOI: 10.1016/S0890-6955(03)00037-3. 4. Shan C., Zhang X., Shen B., Zhang D. An improved analytical model of cutting temperature in orthogonal cutting of Ti6Al4V. Chinese Journal of Aeronautics, 2019, vol. 32 (3), pp. 759–769. DOI: 10.1016/j.cja.2018.12.001. 5. Barzegar Z., Ozlu E. Analytical prediction of cutting tool temperature distribution in orthogonal cutting including third deformation zone. Journal of Manufacturing Processes, 2021, vol. 67, pp. 325–344. DOI: 10.1016/j. jmapro.2021.05.003.
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