Heat partition effect on cutting tool morphology in orthogonal metal cutting using finite element method

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. Finally, the effect of the cutting speed on the heat partition coefficient and the cutting force is investigated and compared with respect to the coated and the uncoated tool.