Multiscale simulation approach to predict the penetration depth of oil between chip and tool during orthogonal cutting of AISI 4140

Cooling lubricants in machining perform important tasks, from cooling and lubrication of the friction partners in contact to the removal of the separated chips. An essential, determining and largely unresolved question in relation to cooling lubricants in machining is to what extent the coolant can get into the cutting zone. The aim of this paper is to address this question by using a multiscale approach to determine the penetration of the cooling lubricant gap. This is achieved by multiscale simulations by means of coupling the results of flow, structural and continuum mechanical simulations. Comparatively, the results of the simulated machining operation are compared with experimental orthogonal cutting tests of AISI 4140.