On the evaluation of the global heat transfer coefficient in cutting

Abstract

The use of numerical simulations for investigating machining processes is remarkably increasing because of the simulation cost is lower than the experiments and the possibility to analyze local variables such as pressures, strains, and temperatures is allowable. Process simulation is very hard from a computational point of view, since it frequently requires remeshing phases and very small time steps. As a consequence, the simulated cutting time is usually of the order of few milliseconds and no steady cutting conditions are generally achieved, at least as far as thermal conditions are concerned. Therefore, nowadays numerical prediction of cutting temperatures cannot be considered fully reliable. In the paper this issue was taken into account: a mixed Lagrangian-Eulerian numerical approach was utilized and the global heat transfer (film) coefficient at the tool-chip interface was derived through an inverse approach. Finally, the dependence of the film coefficient on pressure and temperature on the rake face was investigated.