Temperature Prediction in Orthogonal Cutting with a Finite Difference Approach

Abstract

Following a brief critical review, this paper reconsiders the temperatures in the tool and chip for ‘classical’ orthogonal cutting operations. A three dimensional temperature analysis based on the thin shear zone model, popular shear zone temperature equations and finite difference techniques is presented and assessed. The cylindrical polar co-ordinate system of nodes developed for the wedge tool has been found to be superior in mathematical accuracy and computer implementation to the cartesian co-ordinate systems commonly used in finite difference temperature methods. The influence of major tool and cut variables on the temperature trends have been numerically studied and shown to be acceptable. A comparison with previous experimental tests run at this University has shown good qualitative correlation for the tool face and flank temperature distributions and quantitative agreement for the average tool-chip interface temperature. A feature of the proposed analysis is that it allows the temperatures in the tool and chip to be predicted from a limited number of basic cutting and thermal quantities. Further, the cylindrical polar co-ordinate system used for the wedge tool is particularly suitable for extending this analytical approach to ‘classical’ oblique cutting operations.