Modeling heat transfer in die milling

• Proposed thermal models are simple and sensitive to the machining conditions.
• Models were validated by other methods applied to solve direct-inverse problems.
• Methods may be used for any part materials, conditions and machining processes.
• 3D model approaches global one when uses mean workpiece temperature.
• Methods can also be extended to analyze cutting fluid performance.

This paper compares two different thermal models by solving computationally direct-inverse problem to estimate the net heat flux and convective coefficient when milling hardened AISI H13 die steel. Global and tri-dimensional transient models were developed and solved by Finite-Volume and Gauss Methods, respectively. Two cutting speeds were considered in dry finishing operation. Experimental temperatures measured by part-embedded thermocouples fed the inverse-problem, which were compared to theoretical temperatures given by direct-problem. Both models are able to estimate the thermal properties for milling processes. Tri-dimensional model approaches global one when using mean temperature of thermocouples. The models agreed with others in the literature.