An enhanced semi-analytical estimation of tool-chip interface temperature in metal cutting

Journal article, 2023

An accurate estimation of the temperature distribution on tool surfaces is of great industrial importance; without it, a reliable prediction of tool wear in machining, especially thermally-induced wear mechanisms such as dissolution-diffusion and oxidation, is deemed impossible. This has promoted the development of semi-analytical models for simulation of the tool-chip interface temperature, which are less time-intensive and reasonably accurate. This study aims to present an enhanced prediction of the tool-chip interface temperature within the context of the available semi-analytical solutions of the heat conduction-advection problem with a moving heat source. A novel approach is presented to obtain the variable heat flux along the tool-chip interface based on a non-uniform contribution of generated heat in the sticking and sliding zones during chip flow. The capability of the enhanced model to simulate the temperature distribution is demonstrated for machining C45 and C50 plain carbon steels using uncoated carbide tools. The predictions are validated against the results of experimental orthogonal cutting tests for the same cutting conditions. A comparative analysis is then performed to underline the importance of incorporating the variable heat flux for reliable predictions of the maximum interface temperature and its location on the rake face. The outlook for future developments is also highlighted.