A novel analytical temprature model development for turning in orthogonal and oblique conditions including the effects of all deformation zones and tool wear

Official URL: https://risc01.sabanciuniv.edu/record=b2583785_(Table of contents)

Modelling the temperature during machining and examining its effect on the workpiece and cutting tool is an important subject that has been researched for many years. The main purpose of modelling the temperature is to achieve increased tool life and surface quality. The tool wear which can affect the tool life and surface quality of the workpiece is significantly depended on the cutting temperature. Modeling the heat generation during the cutting processes such as orthogonal cutting, oblique cutting, and turning can be helpful for predicting the tool wear. This study introduces a novel model for the prediction of temperature in the cutting tool while the effects of all three deformation zones are considered. The proposed model considers the effect of cutting-edge radius and the third deformation zone for the first time in the literature in terms of temperature prediction using thermo-mechanical approach with dual-zone friction model. The material behavior is defined by the Johnson-Cook constitutive model. For the calculation of heat flux on the rake and flank faces, a dual-zone model was used. The temperature distributions at the tool-chip and tool-workpiece boundaries were determined analytically, and the temperature distribution inside the tool was calculated using the Finite Difference Method. The developed model was modified to include the effect of flank wear on the cutting temperature. The proposed models are verified experimentally and a good agreement is observed between the model predictions and the test results. This study also examined the effects of cutting-edge geometry and cutting conditions on cutting temperature, which can be used in optimized selection of cutting parameters and tool geometry in industrial applications.