Analysis of thermal fields in orthogonal machining with infrared imaging

The validation of a previously developed finite difference temperature prediction model is carried out for orthogonal machining process with a high precision infrared camera set-up, considering the temperature distribution in the tool. The thermal experiments are conducted with two different materials; Al 7075, AISI 1050, with two different tool geometries; inserts having a rake angle of 6° and 18°, for different cutting velocities and feedrates. An infrared camera set-up is utilized for the thermal experiments. The results of the high precision infrared thermal measurements are compared with the outputs of the finite difference temperature model, considering the maximum and the mean temperatures in the tool–chip interface zone and the temperature distributions on the tool take face. The maximum tool–chip interface temperature increases with increasing cutting velocity and feedrate. The relationship between the maximum tool–chip interface temperature and the rake angle of the tool is not distinctive. The experimental results show good agreement with the simulations.