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MANUFACTURING SCIENCE

Heat Generation & Cutting Tool Temperature

2009

LIST OF FIGURE
Page

Figure 1 Figure 2 Figure 3 Figure 4

Source of Heat Generation in Machining. Apportionment of Heat amongst Chip & Tool & Blank. Typical Temperature Distributions in Cutting Zone. Cutting Temperature T as a Function of Cutting Speed V, Feed f, and Depth of Cut d. Machine Tool for Bone Cutting. Cutting Temperatures in Up & Down-Cutting. Influence of Cutting Speed in Cutting Temperature & Cutting Force. Temperature of Cutting Edge Using Cutting Tool and Bone cooled at -5C. Effect of Temperature on the Yield Stress.

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4 6 7 7

Figure 5 Figure 6 Figure 7 Figure 8

8 9 10 10 10

Figure 9

Figure 10(a) Tool Temperature in 78.5 (m/min) in 110 (mm) Cutting Length. Figure 10(b) Tool Temperature in 51 (m/min) in 110 (mm) Cutting Length. Figure 11 Figure 12 Measured Surface Roughness in m/min.

Temperature Distributions at the Drill Tip after 12.7 mm Depth of Drilling at Peripheral Cutting Speeds. Influences of Coating Material on Temperature Distribution. The Variation of Cutting Force and Tool tip Temperature in Different Rake Angle. The Cutting Force and Temperature Due to the Rake Angle in Difference Feedrate. The Cutting Force and Temperature Change Due to the Feedrate in Different Approaching Angle

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Figure 13 Figure 14

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Figure 15

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Figure 16

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LIST OF FIGURE
Page

Figure 17

The Cutting Force and Temperature Due to the Feedrate in Different Rake Angle

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TABLE OF CONTENT
Page 1.0 INTRODUCTION 1.1 1.2 Temperature in Cutting Tool .. Sources and Causes of Heat Generation and Development of Temperature in Cutting Tool . Distribution of Cutting Tool Temperature . Cutting Tool Temperature Determination .. Controlling the Cutting Temperature .. Theory Related to the Cutting Tool Temperature .. 1

1 2 3 4 5

1.3 1.4 1.5 1.6

2.0

HEAT GENERATION AND CUTTING TOOL TEMPERATURE CURRENT RESEARCH 2.1 A Cutting Temperature of Bone Machining for Orthopedic Robotic Surgery ... Tool Temperature and Surface Quality in Hot Machining of Hard-to-Cut Materials ......

2.2

2.3 2.4

Tool Temperature in Titanium Drilling ... Transient Temperature Distributions in Coated Carbide Cutting Tools Effect of Rake Angle and Approaching Angle on Cutting Force and Tool Tip Temperature .

11

13

2.5

15

1.0

INTRODUCTION

1.1

Temperatures in Cutting Tool

As in all metalworking processes where plastic deformation is involved, the energy dissipated in cutting is converted into heat which, in turn, raises the temperature in the cutting zone. Because of the very large amount of plastic strain involved in metal cutting, it is unlikely that about 1% of the work done is stored as elastic energy (which can be neglected), the remaining 99% go into heating chip, the tool and the work [1]. Temperature rise is a very important factor in machining because it is a major adverse effect such as [2]: a. Excessive temperature lowers the strength, hardness, stiffness, and wears resistance of the cutting tool; tools also may soften and undergo plastic deformation; thus tool shape is altered. b. Increased heat causes uneven dimensional changes in the part being machine making it difficult to control its dimensional accuracy and tolerances. c. Excessive temperature rise can induce thermal damage and metallurgical change in the machined surface, adversely affecting its properties.

However, often the high cutting temperature helps in reducing the magnitude of the cutting forces and cutting power consumption to some extent by softening or reducing the shear strength, of the work material ahead the cutting edge. To attain or enhance such

benefit the work material ahead the cutting zone is often additionally heated externally. This technique is known as Hot Machining and is beneficially applicable for the work materials which are very hard and hardenable like high manganese steel, Hadfield steel, Ni-hard, Nimonic etc [3].

1.2

Sources and Causes of Heat Generation and Development of Temperature in Cutting Tool.

During machining heat is generated at the cutting point from three sources, as indicated in Figure 1. Those sources and causes of development of cutting temperature are[4]: a. Primary shear zone (1) where the major part of the energy is converted into heat.

b. Secondary deformation zone (2) at the chip tool interface where further heat is generated due to rubbing and/or shear. c. At the worn out flanks (3) due to rubbing between the tool and the finished surfaced.

The heat generated is shared by the chip, cutting tool and the blank. The apportionment of sharing that heat depends upon the configuration, size and thermal conductivity of the tool work material and the cutting condition. Figure 2, visualises that maximum amount of heat is carried away by the flowing chip. From 10 to 20% of the total heat goes into the tool and some heat is absorbed in the blank. With the increase in cutting velocity, the chip shares heat increasingly [4].

Figure 1: Source of Heat Generation in Machining

Figure 2: Apportionment of Heat amongst Chip, Tool & Blank

1.3

Distribution of Cutting Tool Temperature

Cutting temperature is not constant through the tool, chip and workpiece. The temperature field in the cutting zones is shown in the Figure 3. It is observed, that the maximum temperature is developed not on the very cutting edge, but at the tool rake some distance away from the cutting edge. Because of the sources of heat generation in machine are concentrated in the primary shear zone and the tool-chip interface, it expected that there will be severe temperature gradient in the cutting zone. From figure 3, the maximum temperature is about halfway up to the tool chip interface. It will be apparent that the particular temperature pattern depends on several factors pertaining to materials properties and cutting condition, including the type of cutting fluid (if any) during machining [2].

Figure 3: Typical Temperature Distribution in Cutting Zone

1.4

Cutting Tool Temperature Determination

Cutting temperature is either; measured in the real machining processes or predicted in machining process design. The mean temperature along the tool face is measured directly by means of different thermocouple techniques, or indirectly by measuring the infrared radiation, or examination of change in the tool material microstructure or micro hardness induced by temperature. Some recent indirect methods are based on the examination of the temper color of a chip, and on the use of thermo-sensitive paints [5].

There are no simple reliable methods of measuring the temperature field. Therefore, predictive approaches must be relied on to obtain the mean cutting temperature and temperature field in the chip, tool and workpiece. For cutting temperature prediction, several approaches are used [5]: a. Analytical methods: there are several analytical methods to predict the mean temperature. The interested readers are encouraged to read more specific texts, which present in detail these methods. Due to the complex nature of the metal cutting process, the analytical methods are typically restricted to the case of orthogonal cutting. b. Numerical methods: These methods are usually based on the finite element modeling of metal cutting. The numerical methods, even though more complex than the analytical approaches, allow for prediction not only of the mean cutting temperature along the tool face but also the temperature field in orthogonal and oblique cutting.

1.5

Controlling the Cutting Temperature

The temperature in metal cutting can be reduced by [6]: a. Application of cutting fluids (coolants). b. Change in the cutting conditions by reduction of cutting speed and/or feed. c. Selection of proper cutting tool geometry (positive tool orthogonal rake angle).

Apart from application of coolants, the simplest way to reduce the cutting temperature is to reduce the cutting speed and/or feed. The next diagrams, Figure 4 show the dependencies between the mean cutting temperature and cutting conditions.

Figure 4: Cutting Temperature T as a Function of Cutting Speed V, Feed f, and Depth of Cut d.

From Figure 4 is obvious, that any reduction of the cutting temperature will require substantial reduction in either the cutting speed or cutting feed, or both (the effect of depth of cut can be neglected). As a negative result, cutting time and therefore production rate will also decrease. To avoid the problem, the best solution to the problem of cutting temperature is the application of coolants.

1.6

Theory Related to the Cutting Tool Temperature

The main sources of heat in machining are; the work done in shearing in primary shear zone, energy degenerate as friction at the tool-chip interface, and heat generated as the tool against the machined surface, particularly for dull or worn tools. Much effort has expended in establishing relationship among temperature and various material process variable in cutting. A inclusive expression for the mean temperature, cutting is [2]:

, in orthogonal

Where the mean temperature is in Kelvin (K),

is the flow stress in Mpa, c is the

volumetric specific heat in kJ/m3.K, and K is the thermal diffusivity (ratio of thermal conductivity to volumetric specific heat) in m2/s. Because the material parameters in equation depend on temperature, it is important to use appropriate values that attuned with the predicted temperature range. Equation shown above explain that the mean cutting temperature increase with workpiece strength, cutting and depth of cut; it decrease with increasing specific heat and thermal conductivity of workpiece material.

An expression for the mean temperature in turning on a lathe is [2]:

Where V is the cutting speed and f is the feed of the tool.

2.0

HEAT

GENERATION RESEARCH

AND

&

CUTTING

TOOL

TEMPERATUE

CURRENT

2.1

A Cutting Temperature of Bone Machining for Orthopedic Robotic Surgery

These studies investigate on measurements of cutting temperature associated with the bone cutting robot for cortical bone. The temperature distribution on the cutting edge immediately after cutting was observed by a thermography near the cutting area, and the internal thermal distribution was also measured using the thermocouple buried near the surface of the workpiece.

Machine tool for bone cutting have been developed using an endmill cutter to assist the total hip and knee joint replacement as shown in figure 5 [7], but one of major problems with this instrument is the possible thermal damage to bone cells caused by the cutting. From previous studies, researchers indicate that cellular necrosis of bone was initiated at 50C [8] and irreparable damage occurred at temperature greater than 70C [8] and the thermal effect on cortical bone tissue can result in the denatured enzyme and membrane proteins causing cellular death. Therefore, it is discussed that the useful cooling method should be applied to solve the problem. The cutting experiment for the temperature measurement was attempted in both dry and wet atmosphere for comparison. The results of the observation done by thermograph.

Figure 5: Machine Tool for Bone Cutting

This experiment using the square endmill of high speed steel with two flutes was used in a machining center (Moriseiki Accumill 4000), and the cutting was carried out using the side edge of the endmill, after the bone specimen was clamped on the cutting force

dynamometer (Kistler 9257 B) mounted on the table of the machining center. The tool 6

geometry has a diameter of 10 mm, the helical angle of 30 and the rake angle of 14. Two measurement approaches were adopted for cutting temperature in this experiment. One is for a careful examination of a thermograph related to the temperature distribution on the cutting edge just after a cutting process by one cutting edge. The used thermograph device (NEC Sanei, TH5104R) was equipped with a magnifying optical lens (NEC Sanei, TH51-377). The other approach to conduct the temperature measurement is to use thermocouple. Temperature measurement is carried out while the rotating endmill cutter passes over the upper part of the thermocouple on the specimen surface.

Results & Discussion: The experimental results are summarized as follows [9]: a. Influence of the cutting conditions had little impact, despite the fact that the applied cutting force did not waver much as shown in Figure 6 & 7. b. The cutting temperature could be lowered to about 30C using the cooled tool and bone at -5C (Figure 8). c. As a result, it is suggested that the necrosis of bone tissue and cell would be avoided under this lowered cutting temperature.

Figure 6: Cutting Temperature in Up & Down-Cutting

Figure 7: Influence of Cutting Speed in Cutting Temperature & Cutting Force

Figure 8: Temperature of Cutting Edge Using Cutting Tool and Bone cooled at -5C

For future research, this experiment is suggest to be perform by using DOE and much variable tool geometry to perform better more reliable results.

2.2

Tool Temperature and Surface Quality in Hot Machining of Hard-to-Cut Materials.

During the two past decades, there has been significant industrial interest in machining hard-to-cut materials. These materials are being used in producing component for electrical, chemical, dental orthopedic, aerospace and nuclear industry, where high dimensional accuracy, tool life and satisfactory surface roughness quality is indeed. For machining of hard-to-cut steel to cut, the cutting tools materials must be harder than workpiece materials. Due to expensive cost of cutting such materials, the different machining methods are being used by manufacturer [10].

In this research, the influence of hot machining method were studied and tool temperature variation when cutting with two speeds 78.5 (m/min) and 51 (m/min) and workpiece surface roughness quality with constant cutting parameter and 300C initial workpiece surface temperaturebwas investigated. The workpiece material and tool used in this study were AISI 1060 steel (45HRC) and uncoated carbide TNNM 120408-SP10 (SANDVIK Coromant) respectively. A gas flam heating source was used to preheating of the workpiece surface up to 300C, causing reduction of yield stress about 15%. In hot machining, preheating of the workpiece can be performed before and/or during cutting. The workpiece temperature was chosen above the recrystallisation temperature, where the yield

stress of materials decreased rapidly [11]. The yield strength of the structural steel (C355) tend to decrease, when its temperature increasing as shown in Figure 9.

Figure 9: Effect of Temperature on the Yield Stress Results & Discussion: The experimental results are summarized as follows [12]: a. The results obtained from measurement at low workpiece temperature (20C, 300C) and with low cutting speed 78.5, 51.5 (m/min) are shown in Figure 10. b. In Figure 11 shows, surface roughness in hot machining got better when the workpiece surface temperature is 300C with less variation, Ra 0.6m with (m/min). c. Hot machining is not only a very useful method for machining of hard-to-cut materials on the rough conditions but also it may use for finishing operation too, when the change of workpiece surface color is not very important. d. In low cutting speeds, the discontinuous form chips produced in machining may be changed to continuous form.

(a)

(b)

Figure 10: (a) Tool Temperature in 78.5 (m/min) in 110 (mm) Cutting Length

(b)

Tool Temperature in 51 (m/min) in 110 (mm) Cutting Length

Figure 11: Measured Surface Roughness in m/min

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2.3

Tool Temperature in Titanium Drilling.

Titanium (Ti) and its alloys are lightweight, corrosion resistant, biocompatible, and high-temperature materials that have been widely utilized in aerospace, medical, military, and sports applications. Because of the inherent properties of Ti, particularly the low thermal conductivity, the tool temperature when machining Ti is high and concentrated at the tool tip. The spatial and temporal distribution of tool temperature in drilling of commercially pure titanium is studied using the inverse heat transfer method. The chisel and cutting edges of a spiral point drill are treated as a series of elementary cutting tools. Using the oblique cutting analysis of the measured thrust force and torque, the forces and frictional heat generation on elementary cutting tools are calculated [13],[14].

Temperatures measured by thermocouples embedded on the drill flank face are used as the input for the inverse heat transfer analysis to calculate the heat partition factor between the drill and chip. The temperature distribution of the drill is solved by the finite element method and validated by experimental measurements with good agreement. The Ti drilling experiment was conducted in a Mori Seiki TV 30 computer numerical control vertical machining center. The workpiece was a 38 mm diameter grade two CP Ti bar. The drill was a 9.92 mm diameter spiral point drill, Kennametal K285A03906, with a S-shaped chisel edge.

Results & Discussion:

The experimental results are indicated that the cutting edge had a lower heat partition factor and higher heat generation rate per length than the chisel edge. The peak temperature of the drill increased from 480C to 1060C as the peripheral cutting speed increased from 24.4 m/min to 73.2 m/min after 12.7 mm depth of drilling. The location of peak temperature moved outside toward the drill margin as the peripheral cutting speed increased. The modeling results also showed the drill temperature did not reach the steady state after a long, 50s drilling time (Figure 12) [15].

For future research, the investigation can be expanded to the drilling condition with the supply of cutting fluid, which is important for the high throughput drilling of Ti. Using the predicted drill temperature distribution and cutting forces, the coupled thermal and mechanical stress analysis of the deformation and stress distributions of the drill can be 11

performed. This study can also be expanded for the drill selection, drill geometry design, and optimization of drilling process parameters to further enhance the productivity of drilling Ti and other advanced engineering materials.

Figure 12: Temperature Distribution at the Drill Tip after 12.7 mm Depth of Drilling at Peripheral Cutting Speeds: (a) 24.4 m/min, (b) 48.8 m/min, and (c) 73.2 m/min

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2.4

Transient Temperature Distributions in Coated Carbide Cutting Tools.

In metal cutting operations, the importance of knowledge on the temperature distribution in cutting tool is well recognized due to the severe effects on the tool life and workpiece surface integrity. In general, three regions of intensive heat generation are distinguished, namely the primary deformation zone (shear plane), the tool-chip interface frictional zone or the secondary deformation zone and the tool-workpiece interface zone [16].

This investigation analyses of the one-dimensional transient temperature distributions in monolayer coated tools. The analytical formula of the transient temperature distributions for the monolayer cutting tools is obtained using Laplace Transform. Computations of the temperature distributions in monolayer coated tools reveal that such factors as the coating material, substrate material and coating thickness have some influence on temperature distributions in monolayer coated tools. The present work provides some data for selecting appropriate coating materials to reduce temperature within coated tools.

Results and Discussion:

The full-field results displayed in Figure 13. The predication is transient temperatures in coated tools during dry cutting. The transient temperature distributions have shown that the thermophysical parameters of coating and substrate materials have huge influences on temperature distributions in monolayer coated tools. The analytical solution method has demonstrated that Al2O3 coating has more effective thermal barrier effect than the other two coating materials. The coating thickness also has some influence on temperature distributions in coated tools [17].

13

(a) Influences of Coating Material on


Temperature Distribution within the Coating

(b) Influences of Tool Substrate Material on (b)


Temperature Distribution within the Coating

Figure 13

(c) Influences of Coating Thickness on


Temperature Distribution within the Coating

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2.5

Effect of Rake Angle and Approaching Angle on Cutting Force and Tool Tip Temperature.

An increase in productivity requires involvement of all production operations, technical possibility for full use or activation of all the available manufacturing facilities. In order to involve all the technological operations, optimum technological processes, optimum tool selection, optimum combination of toolworkpiece material and determination of optimum cutting variables and tool geometry must be considered. An increase in cutting speed can reduce machining hour, but this is the most important factor in reduction of tool life. Due to more demanding manufacturing systems, the requirements for reliable technological information have increased. This calls for a reliable analysis in cutting in the cutting zone (cutterworkpiecechip system). As the mechanics of cutting in this area are very complicated, i.e. various laws continuously interact, it is not possible to make any precise statements about their mutual influences [18]. This investigation deals with the comparison of measured and calculated results of cutting temperature variation generated on the tool tip in turning for different cutting parameters and different tools having various tool geometries while machining AISI 1040 steel hardened at HRc 40. The geometric variables (approaching angle and rake angle) of the tool were changed using selected cutting parameters; thus, the cutting force components and temperature variations on tool face (in secondary shear zone) were determined. The selected cutting variables and the tools in different geometries were tested practically under workshop conditions. The experimental temperature measurement and assumed plastic deformation zone led to the following empirical relationship [19].

Where Tm is the maximum temperature rise of the chip at rake face, which has a contact length of lt. The non-dimensional number is the ratio of the plastic layer thickness over the deformed chip thickness hc on the rake facechip interface. RT is a non-dimensional thermal number given by;

15

Where, V is the cutting velocity, h uncut chip thickness, ct is the thermal conductivity of workpiece (W/(mC)). From the geometry of orthogonal cutting, the chip-rake face contact length lt can be predicted as: ( )

Where c is the shear angle, a is the friction angle and r is the rake angle.

Results and Discussion: a. Effect of approaching angle on tool tip temperature The main cutting edge approaches the workpiece with approaching angle. In large approaching angle, the cutting forces are distributed over a shorter section of the cutting edge. Since the main cutting edge enters and leaves the cutting zone suddenly at 90 of approaching angle it is subjected to maximum loading and unloading. The main cutting force was maximum at = 90. Therefore, the optimum approaching angle was obtained as 60~70. The tool tip temperature was maximum at 45 and minimum at 90. In Figure 14, for the 0.2mm/rev of feedrate and rake angle of 6, tool tip temperature was decreased. As a result, for the changing of rake angle in range of 6~20, temperature was decreased. If both cutting force and temperature level were considered together, the optimum approaching angle could be assumed as 75 [20]. b. The Effect of rake angle on main cutting force and tool tip temperature Rake angle has an important effect on the all cutting force components and also on the tool tip temperature. As shown in Figure 15, the experiments were carried out with the tool having the same approaching angle of 75 and different feedrates as 0.16, 0.20, 0.25 and 0.30 mm/rev. By increasing positive rake angle, the cutting forces were decreased and less force/power was required. The reason is that the tool can plunge into the workpiece easily. Positive rake angle produces higher shear angle; therefore, it helps to reduce cutting forces. It also leaves a better surface finish since it assists the chip to flow away from the workpiece. But, excessive rake angle weakens the tool. It

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was obtained that it was contrast to the increased rake angle; the tool tip temperature values were decreased for different approaching angles. This can be explained in terms of increased toolchip contact length. As a result, if the cutting forces and temperature were considered together, the optimum rake angle could be assumed as 12 [20]. c. It was observed that all cutting forces were increased when the feedrates were increased. Optimum machining condition was obtained at = 0, = 75 when the results of force and temperature variation were investigated together (Figure 16). As a result of this investigation, by considering the cutting forces and temperature together, the optimum approaching angle was found as 75, and the rake angle was found as 12 [20].

Figure 14: The Variation of Cutting Force and Tool tip Temperature in Different Rake Angle

Figure 15: The Cutting Force and Temperature Due to the Rake Angle in Difference Feedrate

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Figure 16: The Cutting Force and Temperature Change Due to the Feedrate in Different Approaching Angle

Figure 17: The Cutting Force and Temperature Due to the Feedrate in Different Rake Angle

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[1]

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[2]

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[3]

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[4]

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[5]

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[6]

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[7]

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[8]

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[9]

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[10]

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[11]

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[12]

M.Davami, M.Zadshakoyan, Investigation of Tool Temperature and Surface Quality in Hot Machining of Hard-to-Cut Materials, Proceedings of World Academy of Science, Engineering and Technology Volume 36 December 2008.

[13]

Rahman, M., Wong, Y. S., and Zareena, A. R., 2003, Machininability of Titanium Alloys, JSME Int. J., Ser. C, 46(1), pp. 107115.

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Yang, X., and Liu, C. R., 1999, Machining Titanium and Its Alloys, Mach. Sci. Technol., 3(1), pp. 107139.

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Rui Li & Albert J. Shih, Tool Temperature in Titanium Drilling, Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109-2125.

[16]

W. Grzesik, M. Bartoszuk, P. Nieslony, Finite Difference Analysis of the Thermal Behaviour of Coated Tools in Orthogonal Cutting of Steels, International Journal of Machine Tools & Manufacture 44 (2004) 14511462.

[17]

Shijun Zhang, Zhanqiang Liu, An Analytical Model for Transient Temperature Distributions in Coated Carbide Cutting Tools, School of Mechanical Engineering, Shandong University, Jinan, 250061, PR China.

[18]

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[20]

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