IEEE Access (Jan 2019)
One-Dimensional Heat Conduction Inverse Modelling of Heat Flux Generated at Tool-Chip Interface in Cutting Inconel 718
Abstract
Inconel 718 has been taken as the difficult-to-machine material for manufacturing aerial turbine disk due to its superior high-temperature resistance and high hardness. Massive heat flux generated at the tool-chip interface, and high tool temperature can induce severe tool wear in cutting Inconel 718 with cemented carbide tool. Determining the generated heat flux and tool temperature in the cutting process is crucial to illustrate the tool wear mechanism. However, there is a shortage of method for integrated estimation of the heat flux generated at the tool-chip interface and temperature distribution within the tool in cutting Inconel 718. In the current study, the one-dimensional inverse heat conduction model was proposed for the integrated prediction of generated heat flux and tool temperature. First, the heat flux generated at the tool-chip interface was inversely calculated with the measured rake face temperature. The heat flux generated at tool-chip interface and heat flux dissipated into tool were increased with cutting speed. Then, the temperature distribution within the cemented carbide tool was determined with the derived analytical solution. Temperature interval between rake face temperature and reverse surface temperature was increased with cutting speed. Finally, the predicted heat flux values were verified accurate with the relative error of less than 3% compared with the research results from the modified Merchant's chip formation model. The proposed model can be used for predicting heat flux and temperature distribution for other tool and workpiece pairs.
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