Application of the inverse heat conduction method in heat flux estimation on the rake face of the cutting tool 

Forooza Samadi[2] , Farshad Kowsary [1]

[2] Department of Mechanical Engineering, Islamic Azad University, Science and Research Branch, Tehran, Iran.
[1] Faculty of Engineering, School of Mechanical Engineering, University of Tehran, Tehran, Iran. 
[1] Corresponding author;
In this work the Sequential Function Specification Method and the commercial software ANSYS are used to estimate the transient heat flux imposed on the rake face of the cutting tool during the cutting operation.  The cutting tool is modelled as a three-dimensional object, and to do that the capabilities of the geometric modelling, mesh generation as well as solver of ANSYS are utilized. The temperatures of the sensors are obtained by solving the direct heat conduction problem within ANSYS, and the random noises are added to them. Reduction in the time expended for modelling and the direct heat conduction solution are advantages of using ANSYS Parametric Design Language (APDL) as a subprogram to solve the inverse heat conduction problem. The stability as well as accuracy of the heat flux estimation is investigated using familiar triangular as well as step heat flux test cases. The effect of noise level, location of temperature sensors and regularization parameter are investigated in order to arrive at an optimal experimental procedure. Finally, typical temperature data during the working condition are used to recover the heat flux at the cutting tool surface

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