Modeling of heat fluxes during machining and their effects on thermal deformation of the cutting tool

The heat fluxes generated by cutting processes lead to thermal deformations in the tools. Particularly, in precision machining it is essential to know the amount of the process heat and its distribution of heat fluxes into tool, workpiece and chips. This paper presents an extended methodology for the calculation of these heat fluxes in machining operations. Additionally, by comparison of experimental results with finite element simulations, the thermally caused tool center point (TCP) displacements in turn-milling operations are discussed. Furthermore, the influence of cooled air on TCP displacements is shown.