CHAPTER 3

CUTTING TEMPERATURES

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Contents
 Introduction

 Measurement of cutting temperatures

 Factors affecting cutting temperatures

 Analytical models for steady-state temperatures

 Finite element and other numerical models

 INTRODUCTION

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Excessive temperature lowers the strength,
hardness, stiffness, and wear resistance of the
cutting tool; tools also may soften and undergo
plastic deformation; thus, tool shape may get
altered
Increased heat causes uneven dimensional
changes in the part being machined, making it
difficult to control its dimensional accuracy and
tolerances
An excessive temperature rise can induce thermal
damage and metallurgical changes in the
machined surface, adversely affecting its
properties
 …INTRODUCTION

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The main sources of heat in machining are
(a) the work done in shearing in the primary shear zone,
(b) energy dissipated as friction at the tool–chip interface, and
(c) heat generated as the tool rubs against the machined surface, especially for
dull or worn tools (tool-work interface)
The three distinct regions of heat generation:
a. Shear zone
b. Chip-tool interface zone
c. Work-tool interface zone
 MEASUREMENT OF CUTTING TEMPERATURES
Using thermocouple principle

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 Tool-work thermocouple technique
 Moving thermocouple technique
 Embedded thermocouple technique
 Compound rake tool method
1. Tool-work thermocouple
technique:
o Both the tool and work
materials have to be
electrically and thermally
conductive for this technique
o The difference in temperature
between the hot and
relatively cold junctions
produce proportional voltage
which is detected or
measured in terms of volts by
a millivolt meter
 …MEASUREMENT OF CUTTING TEMPERATURES
2. Moving thermocouple technique:

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o This method is useful to study the
gradual rise in temperature of
continuous chip at low and moderate
cutting velocities

3. Embedded thermocouple technique:

o Useful for milling and surface grinding
processes. The temperature is maximum
when the thermocouple bead comes very
near to the milling cutter

4. Compound rake tool method:

o Developed to measure the chip-tool
interface temperature along the rake
surface by the thermocouple technique
 FACTORS AFFECTING CUTTING TEMPERATURES
 Among the process parameters
cutting speed shares the greatest

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where V is the cutting speed
influence on cutting
temperatures and f is the feed of the tool,
Approximate values of the
 Since cutting forces generally
don’t vary strongly with cutting exponents a and b are a = 0.2
speed, increasing the cutting and b = 0.12 for carbide tools
speed increases the rate at which and a = 0.5 and b = 0.375 for
energy is dissipated through high-speed steel tools.
plastic deformation and friction,
and thus the rate of heat
generation in the cutting zone
 Increasing the feed rate also
increases heat generation and
cutting temperatures
 Particular empirical expression
for the mean temperature in
turning on a lathe is given by
Tmean  V a f b
 …FACTORS AFFECTING CUTTING TEMPERATURES

 The depth of cut and the rake angle, also influence cutting

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temperatures
 Material properties also strongly influence cutting
temperatures. Cutting temperatures are higher for harder work
materials because cutting forces and thus energy dissipation
are increased.
 Thermal properties of the work material that influence cutting
temperatures include the thermal conductivity k and heat
capacity ρc.
 Peak tool–chip interface temperatures are influenced by the
tool nose radius and included angle. Increasing the nose
radius reduces the peak temperature by reducing the
maximum uncut chip thickness and distributing frictional
energy more evenly over the cutting edge. Reducing the
included or wedge angle (by increasing the rake or relief
angles) increases the peak temperature by reducing the area
through which heat can diffuse from the cutting edge through
the tool.
 ANALYTICAL MODELS FOR STEADY-STATE
TEMPERATURES

 Analytical models in this context are used to

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predict cutting temperatures
 The assumed work material enters at initial
temperature θi and is heated by two plane heat
sources of strength Ps and Pf, representing heating
due to plastic deformation along the shear zone
and frictional heating along the tool rake face
 Assume a steady-state and neglect flank friction,
which would introduce a third heat source.
 …ANALYTICAL MODELS FOR STEADY-STATE
TEMPERATURES
 In Loewen and Shaw’s model, θs is given by

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𝛤1 𝑃𝑠 𝛤1 𝑢𝑑
𝜃𝑠 = + 𝜃𝑖 = + 𝜃𝑖
𝜌𝑐𝑎𝑏𝑉 𝜌𝑐

 Where Ps is the deformation power, which for orthogonal

cutting is given by
𝑎𝑐
𝑃𝑠 = 𝑉 𝐹𝑐 − 𝑃 = 𝐹𝑠 𝑉𝑠
𝑎
ud is the specific deformation power. Γ1 is the proportion of
the deformation energy entering the chip. a is the
undeformed chip thickness, ac the deformed chip thicknes
and b is the width of cut
…ANALYTICAL MODELS FOR STEADY-STATE
TEMPERATURES

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…ANALYTICAL MODELS FOR STEADY-STATE
TEMPERATURES

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 …ANALYTICAL MODELS FOR STEADY-STATE
TEMPERATURES

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Based on Jaeger’s solution for a plane heat source sliding on a
half space, Γ1 can be estimated as:

Where k, ρ, and c are the thermal conductivity,

1 density, and specific heat of the work material
1 
k γ is the strain in the chip
1  1.328
 cVa

The frictional temperature rise θf is given by:

0.377𝛤2 𝑃𝑓 𝑉𝑐 𝐿𝑐 𝜌𝑐
𝜃𝑓 = , 𝐿2 =
𝑏𝑘 𝐿2 4𝑘

Lc is the tool–chip contact length; Pf is the frictional power,

which for orthogonal cutting is given by:
a
Pf  PV
ac
 …ANALYTICAL MODELS FOR STEADY-STATE
TEMPERATURES

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and Γ2 is the proportion of frictional energy flowing into the chip.
Again using Jaeger’s friction slider solution, Γ2 can be estimated
by: B
Pf  i   s
bkt
2 
B Pf
Pf  0.377
bkt bk L2
Where the representative symbol B is:

& kt is the thermal conductivity of the tool material Ar is the aspect

ratio of the contact area, given by
 FINITE ELEMENT AND OTHER NUMERICAL
MODELS

 Marusich and Ortiz’s analysis is a

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representative example or current finite element
model for machining temperatures.
 The governing thermal equation in this model
is a weak form of the energy balance equation,

  cTdV   hdS   q.dV

Bt Btq Bt

where
Bt is the boundary of a given deforming volume at
time t
(Neumann boundary)
ρ is the density
c is the specific heat
T is the spatial temperature field
η is an admissible virtual temperature field
h is the outward heat flux through the surface
q is the heat flux
s is the distributed heat source density
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