Finite element analysis of thermal behaviour in metal machining - 1st report, influence of thermophysical properties on cutting temperature

The finite element method has been successfully employed to investigate thermal behaviour in metal machining. The present paper concentrates on cutting temperature which is affected by the thermophysical properties of both work and tool materials, and the coefficient of heat transfer of a coolant. The use of a high-thermal-conductivity tool such as diamond is more effective in reducing the rake temperature than the use of a coolant. This tendency becomes more obvious when a low-thermal-conductivity material such as titanium alloy is machined. However, the cutting edge of a high-thermal-conductivity tool is subjected to an increased mechanical load due to a temperature drop in the work and chip materials; the increase of flow stress requires an increase in the cutting energy in the deformation zone. The predicted rake temperature, based on the shear plane cutting model, is in fairly good agreement with the experiment, though a better result is given by the finite element machining simulation in conjunction with precise material properties.