Heat Flux Density Distribution Differences in Four Machining Processes of AlSi7 Block: MQL Drilling, Tapping, Reaming and Dry Milling

Dry machining remains an objective for aluminum parts in the automotive industry. One of the limitations is the geometrical thermal distortion induced by the heat flux generated by cutting operations. This paper aims at comparing the heat flux distribution and intensity generated in drilling, tapping, reaming and milling. The heat flux is identified by means of an inverse heat conduction method thanks to thermocouple embedded. An iterative identification algorithm enables to identify the heat flux distribution through a best fit of the experimental and calculated temperatures. The comparative analysis of heat flux-related values shows that drilling is the most critical operation with regard to the heat flux induced in the part.