Research on inverse problems of heat flux and simulation of transient temperature field in high-speed milling

Cutting temperature is an important factor which directly affects cutting tool wear, cutting tool life, machined surface quality, and accuracy in the high-speed machining (HSM) process. It is very important to study the distribution law of cutting temperature for the HSM process. In this paper, the self-developed embedded temperature measuring tool holder system (ETMTHS) is employed to measure the continuous temperature of carbide end milling tool tip. The dynamic temperature field model of solid cemented carbide milling cutter is established by using heat source method, and the heat flux in power series form is solved by using the particle swarm optimization (PSO) algorithm. At the same time, an optimization algorithm to solve the inverse problem of heat conduction is given. The solution of heat flux is converted into the solution of the optimal value problem. Using optimization algorithm, the inverse heat conduction problem can be solved successfully. The temperature and its gradient distribution of solid cemented carbide milling cutter are obtained by analyzing the continuous milling temperature of ANSYS simulation. The comparison results show a good agreement between the simulation temperature and measuring temperature.