Numerical and experimental determination of contact heat transfer during orthogonal cutting

During the cutting process, a large part of the mechanical work is converted into heat, which is dissipated to the environment via the chip, the tool and the workpiece in dry machining. The heat flux partition in the cutting zone depends on the contact heat transfer between the workpiece and the tool. In most cutting simulations to date, the contact heat transfer is assumed to be thermal resistance-free contact, which leads to an overestimation of the heat flux into the tool. In this work, a pressure and temperature dependent contact heat transfer model was derived and implemented in the numerical cutting simulation. The model parameters for dry machining of AISI 1045 with carbide tools were calibrated experimentally. The heat distribution determined with the model provided assured accuracy for orthogonal machining with low uncut chip thickness and thus established a basis for the investigation of the process parameters on the tool temperature.