Experimental Study and Modelling of Heat Transfer in Milling of Titanium Alloys

Abstract: The purpose of this project is studying heat transfer to indexable cutting tools during milling of a selection of titanium alloys, relevant to the industry. To achieve this goal, both experimental and theoretical models were contemplated to formulate the current thesis. The experimental set-up was designed and executed at Seco Tools AB, supporting the project as industrial collaborator. The thermal simulation was modelled at a commercial software of finite element (COMSOL Multiphysics), with an innovative approach of heat rate input, based on the power involved in the machining process, the contact area of the tool and the heat partition. The findings of this project will help to develop more efficient tools and contribute to a deeper understanding of milling processes and thermal behaviour in interrupted cutting. At a practical level, the implications for metal cutting industry and academia, reside in obtaining an experimental methodology available, tested and documented to measure cutting tool temperatures during milling, replicated by means of a thermal model. This complementary approach, allows to have a digital baseline able to reproduce machining conditions in a fast, repeatable and non-intrusive method while acquiring additional experimental data to supply to the model. The heat transfer model has been demonstrated to be accurate and reliable, considering the novelty of the methodology used. Furthermore, intermediate measurements, such as emissivity quantification, have provided specific knowledge around the technique that will contribute to more complex analysis in the future.