A three-dimensional analytical model for transient tool temperature in cutting processes considering convection

• Published in: CIRP journal of manufacturing science and technology Vol. 43; pp. 1 - 14
• Main Authors: Liu, Hui, Rodrigues, Lillian, Meurer, Markus, Bergs, Thomas
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.07.2023
• Subjects: Cooling; Modeling; Orthogonal cutting; Thermal effect; Cooling; Thermal effect; Modeling; Orthogonal cutting
• ISSN: 1755-5817; 1878-0016
• DOI: 10.1016/j.cirpj.2023.02.003

The thermal load of the cutting tool is an important process state parameter that directly influences tool wear and thus the dimensional accuracy of the workpiece. Due to limited accessibility and sensor configuration, it is difficult to monitor tool temperature during the machining process, hence cutting parameters cannot be optimally adjusted to the thermal loads. In order to solve this problem, analytical models of tool temperature are increasingly applied in practice. So far, the available temperature models only consider dry process conditions, and the effects of convective cooling in non-continuous heat sources have not been addressed. Therefore, a new 3D temperature model for cutting tools that incorporates the cooling effect is proposed in this work. This model has a simple expression and is easy to solve. To evaluate the applicability of the model, orthogonal cutting tests were performed under both dry conditions and with high-pressure cutting fluid supply. The accuracy of the model for temperature prediction has been demonstrated by comparing the experimental and simulated temperature distributions. In addition, the thermal properties of the tool material on the temperature development were also analyzed.