The development of a hybrid cutting model for workpiece temperature distribution via advection heat partition approach

This paper presents a novel hybrid cutting model for the prediction of workpiece temperature distribution during the dry milling process of compacted graphite iron (CGI). The hybrid model consists of an analytical force model based on a mechanistic approach and finite element analysis (FEA) based on the thermal model. The heat generated during the milling process transferred to the workpiece is computed via the advection heat partition model. The workpiece temperature distribution obtained through the heat loads, using as boundary conditions in the FEA, was calculated by means of cutting forces. The developed force and thermal models have been experimentally validated, and good agreement between the measured and calculated results has been observed. The energy and active work calculations show that by doubling the feed during CGI milling, an energy saving of about 10% is achieved despite almost doubling the cutting forces.