Temperature and strain measurement during chip formation in orthogonal cutting conditions applied to Ti-6Al-4V

This work presents simplified models for strain and temperature measurement during orthogonal cutting process applying Ernst-Merchant theory and considering a 2-D steady state heat conduction problem. In order to validate the thermal model experiments with high speed imaging and with Infrared imaging were performed. The results of the infrared thermal measurements were compared with the outputs of the temperature model, considering the average temperature on the shear plane and temperature distribution. Also video analysis technique was developed to obtain shear strain in a precise way compared with Ernst-Merchant classical analysis. Experiments were conducted in a specially adapted milling machine for different low cutting velocities and feedrates.