Finite element analysis of thermal effects in orthogonal machining
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A finite element-based computational model is developed to determine temperature distribution in an orthogonal metal cutting process. The model is based on multi-dimensional steady-state heat diffusion equation along with heat losses by convection-radiation film coefficients at the surfaces. The models for heat generations within primary and secondary zones and in the rake face due to friction at the tool-chip interface are discussed and incorporated in the finite element model. Additionally, the model takes into account the geometry of the workpiece/chip/tool and the temperature-dependent thermo-physical properties of the materials. A parametric study is carried out to predict quantitatively the increased temperature level in the tool with increased cutting speed. The results are presented for the machining of high-speed carbon steel and for a range of cutting speeds and cooling conditions.