Analytical model of the temperature distribution in the cutting tool for orthogonal cutting process

Abstract

This work presents an analytical model of the tool temperature distribution field for the cutting process with a new geometrical boundary assumption regarding the current models in the literature. Most of the mechanical energy during metal cutting is converted into thermal energy. Besides, many serious problems such as thermal stress distribution, surface burning, work hardening and tool wear can be induced by the excessive cutting heat generated during the cutting process. Furthermore, in interrupted processes tools are subjected to cyclic heating, and may fail by thermal fatigue mechanisms. An accurate analysis of the cutting temperature is a possible basis for predicting and better understanding the main metal cutting issues. Modeling of cutting processes allows the productivity of cutting processes and costs savings to be improved by optimizing cutting conditions and by avoiding or reducing the need to perform costly and laborious experimental tests. Thus, the main objective of this bachelor thesis is to contribute to the research of modeling for the cutting process, developing an analytical model with finite three-dimensional Green's Function in order to predict time-variant temperature fields in the tool. For this purpose, this analytical model will be compared to previous thermal models in the cutting technology's state of the art for the stationary and the transient state. Moreover, orthogonal cutting experiments were conducted to validate the model developed, which presented less than 6% of relative error for the edge of the tool. Finally, after good accordance of the results, it was possible to accomplish a step forward to apply this model to a milling process.