Measurement of Cutting Temperature in Interrupted Machining Using Optical Spectrometry.

This research presents an experimental study focused on measuring temperature at the tool flank during the up-milling process at high cutting speed. The proposed system deals with emissivity compensation through a two-photodetector system and during calibration. A ratio pyrometer composed of two photodetectors and a multimode fiber-optic coupler is employed to capture the radiation emitted by the cutting insert. The pyrometer is calibrated using an innovative calibration system that addresses theoretical discrepancies arising from various factors affecting the measurement of cutting temperature. This calibration system replicates the milling process to generate a calibration curve. Experimentally, AISI 4140 steel is machined with coated tungsten carbide inserts, using cutting speeds of 300 and 400 m/min, and feed rates of 0.08 and 0.16 mm/tooth. The results reveal a maximum recorded cutting temperature of 518 °C and a minimum of 304 °C. The cutting temperature tends to increase with higher cutting speeds and feed rates, with cutting speed being the more influential factor in this increase. Both the pyrometer calibration and experimental outcomes yield satisfactory results. Finally, the results showed that the process and the device prove to be a convenient, effective, and precise method of measuring cutting temperature in machine processes.

Influence of Tilting Angle on Temperature Measurements of Different Object Sizes Using Fiber-Optic Pyrometers.

This article presents a new model of optical power gathered by a fiber-optic pyrometer when there is a tilting angle between the fiber longitudinal axis and the vector perpendicular to the tangent plane of the emitted surface. This optical power depends on the fiber specifications, such as the diameter and the numerical aperture (NA), as well as the object parameters, including its diameter, emissivity, and tilting angle. Some simulations are carried out using other pyrometers from the literature without tilting to validate the model. Additional simulations with different optical fibers, object sizes, and distances at different tilting angles allow us to describe the behavior of the pyrometer when the object is smaller than the optical fiber field of view (the light cone defined by its NA). The results show that for a finite surface object, the power collected by the optical fiber is affected by changes in the tilting angle, greater tilting lesser gathered power, and reaching the maximum power when the field of view of the fiber covers up the entire object, as expected. On the other hand, additional equations are presented to describe the maximum tilting angle, and distance that allow the maximum power gathered for a determined object diameter and fiber, avoiding temperature measurement errors.