Analysis of the Frictional Heat Partition in Sticking-sliding Contact for Dry Machining: An Analytical-Numerical Modelling

Dry high speed machining is associated with high temperatures which strongly affect the chip formation mechanisms, tribological conditions, workpiece surface integrity, tool wear and then the tool life. To predict the temperature distribution in the tool-chip system, the frictional heat partition, in sliding zone of the tool-chip contact, should be properly taken into account. The determination of the heat flux flowing into the tool is still a challenging issue that affects the models accuracy in machining. Despite the fact that an extensive published literature has been focused on the modeling of the tribological conditions in machining, the thermal aspects of the tool-chip contact require further investigations. In the present work, an analytical-finite element model is presented. The model is compared to the experimental cutting forces for a wide range of cutting speeds. The coupling between the secondary shear zone and the frictional heat partition is also presented.