Simultaneous real time estimation of heat flux and hot spot temperature in machining process using infrared camera

Abstract

This article presents a methodology to simultaneously estimate the heat flux and the hot spot temperature in real time by solving an Inverse Heat Conduction Problem (IHCP). Thus, this study is useful to support the development of practical tool wear monitoring systems and to improve the comprehension of temperature distribution on the tool in machining process. In addition, the use of an IR camera avoids the need to attach thermocouples on the sample. In order to achieve this, a filter coefficient technique is used. Temperatures measured in accessible position on the face of the ceramic tool were used as input data for the problem using an IR camera with a measurement rate of 30 Hz. A monitoring software (Real Time Heat Flux Monitor) which was used in a real case scenario was developed. This software allows the user to monitor heat flux, hot spot temperature and the temperature field in real time without prior knowledge of IHCPs. The results revealed an estimated heat flux in the order of 1.41 × 107 W/m2 and the hot spot temperature reached approximately 700 °C. These results were compared with the Function Specification offline technique, which is well known in literature.

Keywords

• Real time heat flux estimation
• Hot spot temperature
• IR camera
• Machining