Analytical model of cutting temperature field in workpiece including uncut chip layer

Abstract

To understand the nature of chip formation in cutting, the study of temperature field in the uncut chip layer of the workpiece is extremely important. In this study, the temperature field for the uncut chip layer is modeled using the heat source projection at different depths of the layer along the cutting speed direction to obtain the different heating times of points at corresponding depths. It is based on the model of the cutting temperature field in the machined surface layer of the workpiece, as proposed in the previous paper of the authors. The temperature distribution in both uncut chip and machined surface layers are thus achieved, and the temperature penetration depths in the machined surface layer are compared with experiment results. The results show that the computed isotherms on the boundary of the uncut chip and machined surface layers are continuous and smooth, indicating that the temperature field model for the uncut chip layer is correct. The temperature field for the nonplanar primary shear plane heat source is also modeled by introducing the curve integral. This is considerably significant in the conduct of further research on the temperature field in micromachining considering size effects and in machining using restricted contact tools, such as groove-type chip breaker tool, double-rake-angled tool, rounded-edge tool, and tool with built-up edge.