A Thermal FEA Modeling of Multiple Machining Processes for Practical Machining Process Optimization

摘要

Surface integrity of machined surfaces has been considered critical as it relates to the sustainability performance of a machined product. A machined surface is often generated by multiple machining processes, the optimization for a sustainable machining process and machined product requires a consideration of the intermediate surfaces generated at each stage. This paper presents a rapid thermal finite element analysis (FEA) model established for cyclic surface removal processes to reveal the thermal mechanics. The model is considered a practical tool to implement a process optimization. The mechanical dynamics are simplified, and it focuses on thermal dynamics to enable fast computation and can be universally applied in different coolant applications including cryogenic machining. A roughing-finishing optimization is discussed based on the study regarding making rapid decisions making about parameter optimization for the multiple stages of machining.