Cutting temperature analysis considering the improved Oxley’s predictive machining theory

Abstract

This article deals with the identification of the temperature distributions in the chip, tool and workpiece based on orthogonal cutting data estimated analytically from the improved version of the Oxley’s machining theory, including the strain-hardening constant (n eq) and the Johnson–Cook (JC) flow stress equation. The improved Oxley’s machining theory and thermal model were separately considered to compute temperature distributions. The initial parameters (δ, C 0, ϕ) and temperature factors (η, ψ) of Oxley’s model were optimized to improve the computation efficiency and estimation accuracy. The thermal model considers the effects of the primary and secondary heat sources. The primary heat source was depicted as a uniformly acting oblique band. The secondary heat source was modeled by applying non-uniform distribution of the heat partition ratio. The estimated results were compared with the published results of an experimental investigation in machining of AISI 1045 steel. It was found that the results of the improved Oxley’s model were closer to the experimental values than the outcomes of its extended version. A detailed set of the temperature distributions was introduced and the estimated temperature values were in good agreement with the experimental results.