Heat Flow Simulation for Dry Machining of Power Train Castings

Dry machining of power train components (eg. cylinder blocks, heads) is very challenging. High heat input due to the lack of coolant can result in an inhomogeneous temperature distribution leading to omni directional distortion. This distortion can be calculated using FEM simulation. It requires however a detailed knowledge about the heat input of each operation. So far this can only be determined by extensive experiments. The aim of this paper is to present a model describing the heat input as a function of cutting parameters and tool geometry. Based on this model the heat input can be calculated. This allows the simulation and optimization of the operation sequence.