Temperature field in modulation-assisted machining

Abstract

Modulation-Assisted Machining (MAM) is a novel machining process where a controlled low-frequency oscillation is superimposed on the tool feed during cutting so as to allow intermittent disengagement of the tool from the workpiece, resulting in discrete chip formation. While MAM has been shown to significantly reduce tool wear when compared to conventional machining, fundamental mechanisms responsible for the reduced tool wear remain unclear. This study explores the role of temperature through in-situ measurement of the cutting tool temperature during MAM. The tool temperature distribution is captured using a medium-wavelength high-speed infrared imaging system. This in-situ data is used to analyze spatiotemporal variations in temperature distribution along the tool rake face during MAM. The results show that the average tool-chip contact temperature in MAM is lower than that in conventional machining under the same material removal rate. An analytical model is presented to capture the periodic heating and cooling cycles in MAM and identify the fundamental factors contributing to tool temperature reduction in the presence of feed modulation. The combined experimental and modeling framework presented in the study serves as a valuable tool for investigating the effect of various modulation parameters on tool temperature distribution and identifying optimal MAM conditions to improve tool performance.