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1、ANINVESTIGATIVESTUDYOFTHEINTERFACEHEATTRANSFERCOEFFICIENTFORFEMODELLINGOFHIGHSPEEDMACHININGSyedAmirIqbal1,PaulTMativenga2,MohammadASheikh2ABSTRACTThispaperisconcernedwiththedevelopmentofanexperimentalsetupandFiniteElement(FE)betweenthechip,thetool,andth
2、eenvironmentduringthemetalmachiningprocesshasanimpactontemperatures,wearmechanismsandhenceontool-lifeandontheaccuracyofthemachinedcomponent.Formodellingofthemetalmachiningprocess,theinterfaceheattransfercoefficientisanimportantinputparametertoquantifyth
3、etransferofheatbetweenthechipandthetoolandtoaccuratelypredictthetemperaturedistributionwithinthecuttingtool.InpreviousstudiesinvolvingFEanalysisofmetalmachiningprocess,theheattransfercoefficienthasbeenassumedtobebetween10-500kW/m2oC(0.49-24.5BTU/sec/ft2
4、/oF),withabackgroundfrommetalformingprocesses(especiallyforging).Basedontheoperatingcharacteristics,metalformingandmachiningprocessesaredifferentinnature.Hencetherewasaneedtodevelopaprocedureclosetometalmachiningprocess,toestimatethisparameterinordertoi
5、ncreasethereliabilityofFEmodels.Tothisend,anexperimentalsetupwasdeveloped,inwhichanuncoatedcementedcarbidepinwasrubbedagainstasteelworkpiecewhilethelaterwasrotatedatspeedssimilartothecuttingtests.Thismodifiedpin-on-discset-upwasequippedwithtemperaturean
6、dforcemonitoringequipment.AFEmodelwasconstructedforheatgenerationandfrictionalcontact.Theexperimentalandmodellingresultsofthedryslidingprocessyieldtheinterfaceheattransfercoefficientforarangeofrubbingspeeds.Keywords:HighSpeedMachining,frictionalcontact,
7、Interfaceheattransfercoefficient1.INTRODUCTIONTheworkdonetoplasticallydeformandshearawayworkpiecematerialduringthemachiningprocessislargelyconvertedintoheat.O'SullivanD,CotterellM.TemperatureMeasurementinSinglePointTurning.JMaterialsProcessingTechnology
8、2001;118:301-308.Thisheatenergyincreasesthetemperaturesofthechip,thetoolandthemachinedsurface.Averysmallamountofthisheatenergyisdissipatedtotheenvironment.Thesecondlargestsourceofheatgenerationduringthemachiningprocessforcaseswhe