Numerical and experimental simulation for heat flux and cutting temperature estimation using three-dimensional inverse heat conduction technique

In this work the heat flux generated in a cutting process is simulated usin g the inverse heat conduction technique based on conjugate gradient method with adjoint equation. A three-dimensional formulation is used both to desc ribe the physical phenomenon and to solve the inverse problem. The machinin g process (turning) is simulated and instrumented with nine thermocouples a t the bottom face of the tool, opposite to its main rake face. The signals are automatically received and processed using a data acquisition system an d a PC-Pentium. The direct solution, adjoint equation and sensitivity probl em are numerically solved using finite volumes method. With this technique the cutting temperatures are estimated for various simulated cutting condit ions. In order to validate the method the MCP is applied in a well-controll ed experiment where the heat flux input is known. An uncertainty analysis i s also presented.