Evaluating Cutting Fluid Effects on Cylinder Boring Surface Errors by Inverse Heat Transfer and Finite Element Methods

Sets of dry and wet boring experiments are conducted to estimate the amount of heat transferred into the workpiece and the cutting fluid heat convection coefficient in a boring operation by an inverse heat transfer method. The temperature distribution in the bore is predicted using a heat transfer model that includes heat convection on the inner and outer bore walls. The developed model is solved by an integral transform approach. The thermal expansion of the bore is then calculated using the finite element method (FEM). Surface error due to the cutting forces is also predicted using FEM and added to the thermally induced surface error to give the total surface error. The actual surface error of bores machined under dry and wet cutting conditions are measured and compared with the predicted surface error. Very good agreement between measured and predicted surface errors is observed. @S1087-1357~00!00802-9#