A model for tracking temperature variation in cold and hot metal working conditions during machining operations

This paper presents a mathematical model that could assist in measuring, monitoring and controlling temperaturevariation in cold and ‘red-hot’ metal working conditions of machining. A numerical analysis techniqueof the temperature distribution, based on the theory of complex applied potential, was carried out usingthe principles of relationship analysis between the paths of heat supply in Cartesian plane when the heat pathsupplied to the material is orthogonal. The high level of temperature involved may effectively be predicted if amathematical relationship that predicts the pattern of temperature distribution in a material is available. A casestudy example in a machining workshop is given. Simulation experiments are then carried out using MonteCarlo to increase the confidence in decision-making and provide data for significance testing. This was usedas an input for testing for significance. Sensitivity analyses were also carried out in order to observe the degreeof responsiveness of model parameters to changes in value. In all, five pairs of comparison were carriedout among different workpiece materials. There are significant differences between workpiece materials madeof steel and copper, copper and zinc, copper and aluminum. However, no significant differences exist in themodel behavior of steel and aluminum, steel and zinc. It was observed that parameters are highly sensitive tochanges in value. The framework could possibly be applied to milling and surfacing activities in the engineeringworkshop. This contribution may be helpful to small-scale enterprises that could not afford sophisticatedand very expensive facilities.