BEM approach to thermal aspects of machining processes and their design sensitivities

Cholik Chan, Abhijit Chandra

Research output: Contribution to journalArticle

8 Citations (Scopus)

Abstract

Elevated temperatures generated in machining operations influence the process efficiency, surface quality, and chip formation mechanics. This paper presents a boundary element method (BEM) formulation for the determination of design sensitivities of temperature and flux distributions for several shape and process parameters in machining operations. This approach is based on direct differentiation (DDA) of the relevant BEM formulation of the problem. The heat transfer and its sensitivities within the tool, the chip, and the workpiece are first calculated separately. A complete model for steady-state machining is then obtained by matching the boundary conditions across the tool-chip, chip-workpiece, and tool-workpiece interfaces. An exact expression for matching is developed to avoid any iterations. The temperature fields and their sensitivities within the workpiece, the chip, and the tool are obtained for various processing conditions. The situation of progressive flank wear and progressive crater wear with continued machining is considered, and its effects on the temperature and flux fields are investigated. The BEM is found to be very robust and efficient for this class of steady-state conduction-convection problems. The application of DDA in conjunction with BEM allows efficient determination of design sensitivities and avoids strongly singular kernels. This approach provides a new avenue toward efficient optimization of the thermal aspects of machining processes.

Original languageEnglish (US)
Pages (from-to)562-575
Number of pages14
JournalApplied Mathematical Modelling
Volume15
Issue number11-12
StatePublished - Nov 1991

Fingerprint

Design Sensitivity
Boundary element method
Machining
Boundary Elements
Chip
Differentiation (calculus)
Wear of materials
Fluxes
Singular Kernel
Surface Quality
Formulation
Shape Parameter
Process Parameters
Temperature Field
Conduction
Temperature
Surface properties
Convection
Mechanics
Heat Transfer

ASJC Scopus subject areas

  • Computational Mechanics
  • Control and Systems Engineering
  • Control and Optimization

Cite this

BEM approach to thermal aspects of machining processes and their design sensitivities. / Chan, Cholik; Chandra, Abhijit.

In: Applied Mathematical Modelling, Vol. 15, No. 11-12, 11.1991, p. 562-575.

Research output: Contribution to journalArticle

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