Determination of temperature distribution in the cutting zone using hybrid analytical-FEM technique

In this study, the temperature distribution in the cutting zone was determined by integrating thermal analytical and simulation models of orthogonal cutting process with uncoated and coated carbide tools. Primarily, 2D FEM simulations were run to provide numerical solutions of temperatures occurring at different points through the chip/tool contact region and the coating/substrate boundary under defined cutting conditions. In addition, an analytical model for heat transfer in the cutting tool and its partitioning, proposed in References [W. Grzesik, P. Nieslony, Physics based modelling of interface temperatures in machining with multilayer coated tools at moderate cutting speeds, Int. J. Mach. Tools Manufact. 44 (2004) 889–901; W. Grzesik, P. Nieslony, A computational approach to evaluate temperature and heat partition in machining with multilayer coated tools, Int. J. Mach. Tools Manufact. 43 (2003) 1311–1317], was employed to generate the input data to computations of the tool–chip interface temperature. The changes of the temperature distribution fields resulting from varying heat flux transfer conditions are the main findings of the FEM simulations. Finally, the analytically and numerically predicted average temperatures were validated against the tool-work thermocouple-based measurements and discussed in terms of relevant literature data.