The generation mechanism of cutting heat and the theoretical prediction model for temperature on the rake face of the cutting tool in Zirconia ceramics

Abstract

Cutting temperature and its distribution are crucial factors influencing tool strength and wear rate, due to the hardness and brittleness of Zirconia (ZrO2) ceramics, significant challenges arise in both direct temperature measurement in the cutting zone and theoretical analysis of cutting heat. Thus, focusing on the turning characteristics of ZrO2 ceramics, this study analyzes the mechanism of cutting heat generation and proposes utilizing thermodynamic state equations to determine the cutting heat source on rake face of tool. Based on the heat source method, a theoretically prediction model for temperature distribution on rake face is established. This model considers primary cutting parameters, workpiece material properties, crack fracture characteristics of the machined surface, and thermal characterizations of the tool material. The relationship between tool wear and cutting temperature is experimentally analyzed to determine the characteristic temperature that indicates the initial stage of tool wear. The validity of the theoretical model is verified, as the predicted results show high consistency with experimental results within the range of experimental parameters, with a relative error within 15.2 %.The results reveal the highest temperature during brittle cutting occurs within the cutting layer area, with the highest temperature occurring approximately 50 μm from the tool tip, followed by a gradual decrease beyond 150-200 μm. This study also demonstrates that cutting heat in ceramic turning does not solely originate from friction heat between tool flank-workpiece but also includes impact heat from tool rake face-workpiece, which under certain cutting parameters exerts a more significant influence on cutting temperature. This model can facilitate the selection and optimization of cutting process parameters for brittle materials and provide a theoretical basis for analyzing the relationship between tool thermal damage, thermophysical properties, and tool wear.