Numerical simulation of thermally induced workpiece deformation in turning when using various cutting fluid applications

The paper describes a combined experimental–theoretical approach for modeling heat generation and transfer processes in turning when using various cutting fluid application techniques for cooling and lubrication, i.e. flood type cutting fluid application, minimum quantity cutting fluid application and dry machining. The developed process simulation was based on the finite element (FEM) method applying the ANSYS V5.5.3 program, which provided the workpiece surface temperatures and thermally induced deformation. The development of the physical model was based on a test workpiece of high stiffness to separate thermal deformation from deformation caused by other factors. The simulation and experimental results compared very well and proved the accuracy of the model. The process model and the system approach were also verified on a “real” industrial workpiece.