A Three-Dimensional Transient Thermal Model for Machining

This article presents an enhanced mathematical model for transient thermal analysis in machining processes. The proposed mathematical model is able to simulate transient tool, workpiece, and chip temperature fields as a function of time for interrupted processes with time varying chip loads such as milling and continuous machining processes such as turning and drilling. A finite difference technique with implicit time discretization is used for the solution of partial differential equations to simulate the temperature fields on the tool, workpiece, and chip. The model validations are performed with the experimental temperature measurement data available in the literature for the interrupted turning of Ti6Al6V-2Sn, Al2024, gray cast iron and for the milling of Ti6Al4V. The simulation results and experimental measurements agree well. With the newly introduced modeling approach, it is demonstrated that time-dependent dynamic variations of the temperature fields are predicted with maximum 12% difference in the validated cases by the proposed transient thermal model.