Chip Temperature Measurement in the Cutting Area During Rough Milling Magnesium Alloys with a Kordell Geometry End Mill

The paper presents the results of measurements of chip temperature in the cutting zone during milling. The main aim of the research was to record and compare the maximum chip temperature in consecutive frames of thermal images. An additional goal may be the influence of changes in technological parameters on the temperature of the chips in the cutting zone. Two grades of magnesium alloys were used for the tests: AZ31 and AZ91HP. The research used a carbide milling cutter with an additional chip breaker, dedicated to effective roughing of light alloys. These tool geometries can assist in the high-performance machining of magnesium alloys by efficiently splitting the chip and consequently reducing friction in the machining zone. This can reduce the cutting area temperature. The results of the research work were showed as exemplary "time" charts. box-plot charts and a summary table, which additionally included an error analysis of the measurement method. On the basis of the tests and measurements performed, it can be concluded that despite the observed chip fragmentation. the obtained temperatures can be defined as the so-called safe milling areas. During the machining tests, the risk of chip ignition during machining was not observed, also the characteristic melting points. which clearly indicates the safety of the milling process of these alloys. It has been observed that with the increase of nu(c) and f(z), there was no increase in the maximum temperature of the chip in the cutting area. This situation only occurs when increasing a(p).