Abstract
It is widely accepted that heat partition and temperature distribution for metal cutting process have a significant effect on the morphological features of the cutting tool. Tool life and cutting accuracy are considerably affected by temperature distribution and heat transfer mechanisms on the tool. When a finite elements model is accurately generated, an understanding of heat partition into the cutting tool without performing experiments can be gained. This study has been completed with the use of uncoated and coated tools in order to predetermine heat partition value entering the cutting tool. In terms of coated tools, tool coating was investigated to assess its effects on heat partition. Finite Element Method was mainly used in combination with the previously generated experimental data in literature. Three-dimensional uncoated and coated models were created and made compatible with finite element modeling software to be able to perform thermal analyses of the cutting process. Finite element transient and steady-state temperature values were calculated and hence the heat intensity value for the cutting tool was determined.
Highlights
Metal cutting process is a removal of a layer of metal, which is called the chip, by a cutting tool
A higher temperature decrease in HSM occurs due to higher cutting speeds which lead to shorter time of contact, smaller contact area, and more heat removal by the chip compared to conventional machining
The higher heat partition value in conventional machining was observed due to low cutting speed which leads to having more contact time and larger contact area of heat penetration
Summary
Metal cutting process is a removal of a layer of metal, which is called the chip, by a cutting tool. Plastic deformation taking place within the workpiece material and frictional interactions between the cutting tool and the chip cause heat generation during the cutting process. A study in terms of temperature distribution and heat partition gives rise to the necessity of the tool coatings in such metal cutting processes. In the thermal effect studies performed in the literature, both cutting tool, workpiece material and cutting medium are modelled. This real-time finite element analysis takes more and more times. The main purpose here is to generate the correct finite element model which is ready to use when deciding the tool coating thickness required for related machining operations [22]. We focused on the physical background of the heat transfer mechanism of orthogonal cutting
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