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Abstract
In this study, the temperature distribution in the cutting zone was determined by integrating thermal analytical and simulation models of
orthogonal cutting process with uncoated and coated carbide tools. Primarily, 2D FEM simulations were run to provide numerical solutions
of temperatures occurring at different points through the chip/tool contact region and the coating/substrate boundary under defined cutting
conditions. In addition, an analytical model for heat transfer in the cutting tool and its partitioning, proposed in References [W. Grzesik, P.
Nieslony, Physics based modelling of interface temperatures in machining with multilayer coated tools at moderate cutting speeds, Int. J.
Mach. Tools Manufact. 44 (2004) 889901; W. Grzesik, P. Nieslony, A computational approach to evaluate temperature and heat partition in
machining with multilayer coated tools, Int. J. Mach. Tools Manufact. 43 (2003) 13111317], was employed to generate the input data to
computations of the toolchip interface temperature. The changes of the temperature distribution fields resulting from varying heat flux
transfer conditions are the main findings of the FEM simulations. Finally, the analytically and numerically predicted average temperatures
were validated against the tool-work thermocouple-based measurements and discussed in terms of relevant literature data.
q 2005 Elsevier Ltd. All rights reserved.
Keywords: Machining; Steels; Temperature distribution; Hybrid modelling
1. Introduction
It is a special kind of technical paradox that relatively
little effort has been directed toward measuring temperature
distribution in the tool, which is correlated directly with its
wear rate. As a substitute various simulation models which
are capable of predicting the tool temperature distribution
with satisfactory accuracy are developed. This trend is
motivated by the strong belief that the substantial
improvement of metal removal efficiency can also be
achieved by more sophisticated modelling of these
processes at a system level, that means by generation of
the house of models [1].
For the past 50 years, metal cutting researchers have
developed many modelling techniques including analytical
techniques, slip-line solutions, empirical approaches
* Tel.: C48 77 4006290; fax: C48 77 4006342.
E-mail address: grzesik@polo.po.opole.pl.
0890-6955/$ - see front matter q 2005 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ijmachtools.2005.07.009
652
653
Fig. 1. The mesh model for a TiC/Al2O3/TiN coated tool used in [13] (a) and shape of the deformed chip after a tool path of 4.0 mm with cutting edge radius of
33 mm and 1460 nodes obtained in the present study (b).
(3)
K58
58
33 mm
0.16 mm
2.0 mm
103.2 m/min
0.5
654
xi
leq
x1 x2
x
C C/C t
l1 l2
lt
(4)
aeq Z
leq
Ceq
(5b)
where Ci, cpi and ri are the volumetric heat capacity, the
specific heat and density of i-layer, respectively.
Calculated values of equivalent conductivity and
diffusivity for the cutting speed of 103.2 m/min
(at corresponding measured cutting temperature of
592.3 8C) are equal to leqZ17.51 W/m K and aeqZ
5.89!10-6 m2/s.
3.2. Determination of the heat partition coefficient
and temperature components
In this modelling case study, two expressions for the heat
partition coefficient proposed by Shaw-RSH [11] and
Reznikov-RR [14] are used. The expression for RSH
coefficient is
1
p
(6)
RSH Z
1 C 0:754lTeq =lW =Aa NT
In Eq. (6), thermal conductivities of work (lW) and
tool (lTZlTeq) materials, thermal number (NT) and area
1
p
1 C 3lTeq =2lW aW =aTeq
(7)
(8)
655
Fig. 2. Distribution of heat sources for ISO P20 uncoated (a) and TiC/Al2O3/TiN (b) coated carbide tools. Cutting conditions as in Table 1.
Fig. 3. Isotherm patterns in ISO P20 uncoated carbide tools (a) and magnification of temperature distribution in the vicinity of the cutting edge (b). Cutting
conditions as in Table 1.
656
Fig. 4. Isotherm patterns in TiC/Al2O3/TiN coated carbide tools (a) and magnification of temperature distribution in the vicinity of the cutting edge (b). Cutting
conditions as in Table 1.
A-P20
M-P20
700
Temperature,C
666.7C
648.9C
A-3L
M-3L
592.3C
600
581.1C
500
103.2 m/min
Tool
Analytical
885.3
777.7
Chip
FEM
635.3
524.5
FEM
679.2
650.6
400
40
60
80
100
120
140
160
180
200
220
657
Table 3
Specification of values of percentage deviations for Figs. 5 and 7
Cutting speed (m/min)
Insert type
Average temperature (8C)
Estimated error range (8C)
Insert type
Average temperature (8C)
Estimated error range (8C)
51.37
62.34
72.24
P20 uncoated
587.62
608.49
624.92
G28.70
G29.30
G25.40
coated withTiC/Al2O3/TiN
547.00
559.15
568.62
G41.00
G43.30
G44.10
103.2
124.69
144.48
178.13
206.4
649.09
G30.60
666.70
G33.00
690.07
G30.50
708.88
G33.40
736.56
G28.90
756.72
G27.80
582.39
G45.80
592.31
G48.00
605.34
G49.00
615.71
G48.50
630.82
G44.00
641.69
G43.20
600
600
500
500
400
300
400
300
200
200
100
100
0
0
0.0000
650.6C
(b) 700
679.2C
Temperature,C
Temperature,C
(a) 700
89.06
0.0005
0.0010
0.0015
0.0020
0.0025
0.0005
0.001
0.0015
0.002
0.0025
Time, s
Time, s
Fig. 6. Average interface temperature trace vs. simulation time for uncoated (a) and three-layer coated (b) carbide tools. Cutting conditions as in Table 1.
5. Conclusions
In this paper, a coupled thermo-mechanical model of
orthogonal metal cutting was used to determine the
distribution of temperature in the tool and the chip as
well as the average toolchip interface temperature.
Moreover, this modelling issue was extended to the
analytical prediction of the average toolchip temperature incorporating equivalent thermal properties for the
multilayer coating applied and corresponding heat
partitioning.
It is shown that the outcomes of the FEM and analytical
models provide quite satisfactory and physically
supported results, for both uncoated and three-layer
coated tools, concerning values and distributions of
cutting temperatures. However, a better accuracy can
probably be obtained by tuning friction parameter and
heat partition to coated tools with real thicknesses (in
this study they were based on the manufacturers data
not on measurements using for instance scanning
microscopy).
It is apparent that the key assumption of the constant
friction coefficient of 0.5 (Coulomb friction) in a FEM
model is not appropriate for machining with coated tools
Average interface
temperature, C
simulation FEM
666.7 679.2
648.9
analytical model
592.3 650.6
581.1
600
500
400
300
200
100
0
P20
L3
Cutting tool material
658
References
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