Prediction Of Convective Heat Transfer Coefficient During Cylindrical Boring

Investigators: A. Gandhi and J. W. Sutherland

Sponsors: PECASE, Kennametal, and Ford

Introduction:

The cylindrical boring process is a machining process widely used in automotive industry, and by other engine manufacturers, for the production of cylinder bores in cast engine blocks. The cylinder boring process affects the cylindricity of machined bores through the cutting forces and the temperature field generated during the cutting operation. Cutting fluids are often used during the machining process for reducing the surface error and increasing the tool life. Spent cutting fluids are one of the most important waste stream elements in metal cutting processes. Growing disposal costs and stricter environmental regulations are forcing manufacturers to reduce or eliminate the use of cutting fluids. To maintain the required tolerances on cylindricity in the absence(or with reduction) of cutting fluids, it is important to understand the relation between the convective heat transfer coefficient of the cutting fluid and the surface error.

Research Plan:

1. Designed experiments shall be conducted to measure the temperature generated during cylindrical boring operation. The temperature shall be measured by mounting thermocouples on the cylinders.

2. The temperatures measured shall be used to predict the fraction of heat transferred into the workpiece and the convective heat transfer coefficient using inverse heat transfer models.

3. The surface error of the machined cylinders shall be determined using Coordinate Measuring Machine.

For additional information contact:

Professor John W. Sutherland

Phone: (906) 487-3395

Fax: (906) 487-2822

email: jwsuther@mtu.edu

http://www.me.mtu.edu/~jwsuther