Analytical Modelling Methods for Temperature Fields in Metal Cutting Based on Panel Method of Fluid Mechanics

Temperature fields and subsequent heat flow into the components chip, tool and workpiece are of major significance for metal cutting. The temperature field in the tool influences for example the type of wear and the tool life and hence the temperatures evolving in the workpiece are responsible for later product quality. However, measurements of temperature fields in metal cutting require experimental efforts and are often prone to measurement errors.The present paper describes an analytical modelling method based on potential theory. Potential functions are successfully applied in other engineering fields, i.e. fluid mechanics and electrostatics. The fact that solutions for the same class of differential equation, namely the Laplace Differential Equation, are required give rise to apply the potential theory to describe the temperature field in metal cutting processes.While first approaches of the theory were more arbitrary, the so called panel method provides a systematic method for consideration of adiabatic boundaries and heat source strengths. In particular, cutting edge geometries and cutting edge radius as well as influence of wear can be considered with this method. Note that complex geometries and non-symmetrical heat sources cannot be covered by conventional analytical models of temperature fields in metal cutting. In terms of validation the modelling outcomes are compared to infrared camera pictures, conventional analytical model outcomes (modified model from Komanduri & Hou) and FEM simulation outcomes.