Cutting temperature prediction in high speed machining by numerical modelling of chip formation and its dependence with crater wear

A study through a finite elements model using the AbaqusTM code is conducted to predict the interface cutting temperature and its dependence with the crater wear mechanism. Unlike the most previous researches, this work is focused on the domain of the high speed machining above 20 m/s. The mechanical and thermal parameters that influence the temperature distribution at the tool rake face are analysed in details. A method based on some analytical preliminary calculations is proposed to determine the adequate values of the friction shear stress and the heat partitioning factor between the tool and the chip. A correlation between specific experiments and simulations is verified in the case of orthogonal cutting of mild steel up to a velocity of 60 m/s. Cutting tests were carried out on a ballistic device equipped with an intensified CCD camera to measure the temperature field into the chip. A good agreement is found with respect to measurements of cutting forces, contact length and temperature. As application, a wear model is coupled with the finite element model through an iterative schema. At each step of calculation, the contact pressure and temperature are updated while the crater grows.

► We investigated the domain of the very high speed machining.
► An accurate model aiming to predict the temperature at the interface is proposed.
► Results are experimentally validated up to 60 m/s.
► Contact is studied by a novel approach of modelling the friction stress.
► Crater growth is simulated by considering mutual effects of wear and temperature.