A Three Dimensional Calculation Approach for the Heat Flux Density Distribution in Face Milling

摘要

In metal cutting, the prediction of thermally induced material alterations, e.g. crack formation, generation of residual tensile stresses, and form deviations of components is of high relevance. This requires the knowledge of the dissipated heat into the workpiece, represented by the heat flux density distribution at the contact area between tool and workpiece. In this work, an approach is presented in which the heat flux density distribution is based on the uncut chip thickness and the heat partitioning in the primary shear zone. A novel analytical model that calculates the uncut chip thickness in dependence of all three spatial dimensions, considering also the tool corner radius is proposed. With this, the heat source can be fully described by knowing the overall amount of heat generated in the primary shear zone during a single cutting edge engagement in milling.