Simulate Thermal Transfer - Face mill on 7050 Aluminum Dry (zero coolant)

[Anonymous]

How can one simulate the thermal transfer from a milling tool carbide insert at 750 degrees C into the base material?   We can assume that 60% of the total thermal energy generated is removed by the very hot chips as they plasticize, ride up the tool and break off of the rotating tool.

We can furhter assume that of the remaining thermal energy (100% - 60%), an additional 15% is transfered through the tool body, tool spindle and then out through the spindle liquid coolant at 96 degree F.

How can we determine how much residual thermal energy not carried away by chips or spindel coolnat is transfered into the base material part that is not machined away?

[John_Holtz]

Hi @Anonymous. Welcome to Fusion.

Machining is a transient process (the tool moves), but Fusion's thermal analysis is limited to steady state (all heat loads and cooling are constant for an infinite length of time). I do not have any suggestions on how you would do a thermal analysis of this with Fusion.

Maybe someone else with experience in machining will have some other suggestions.

[Anonymous]

John,

Thank you for the reply back and for clarifing what Fusion can do.  Hypothically, if I wanted to attempt this transient type of simulation, what Autodesk software product would I need to begin to consider? 

If you are not comfortable making a recomandation, would be able to forward me to the most appropriate resouce so I could follow up.  Thank you.

Regards,

Bob Jensen

[Anonymous · Accepted solution]

There is not a software package out there that I would expect to give accurate results especially if you're just approximating the percent that different processes contribute to heat removal.

From a cfd perspective...This is a conjugate heat transfer problem with multiphase flow and turbulence models and moving domains. EDIT: I just saw you said no coolant so at least it's not multi phase.

From an FEA perspective its explicit dynamics.

All of these processes are highly transient.

The amount of computational power required to solve this would be huge and take several days.

ANSYS is the only provider that has advanced enough multiphysics models to get you in the ballpark so if you really want to give it a shot...start there. *CFX is big with turbo machinery so that may at least be suited to the rotation of a tool.

[Anonymous]

Sean,

Thank you for the clarification of the difficulty of this problem.

Regards,

Bob