Materials

& Design
Materials and Design 28 (2007) 2329–2335
www.elsevier.com/locate/matdes

Investigation of chip-back temperature during machining depending

on cutting parameters
Ihsan Korkut a, Mehmet Boy b, Ismail Karacan c, Ulvi Seker a,*

a
Gazi University, Technical Education Faculty, 06500 Besevler, Ankara, Turkey
b
Zonguldak Karaelmas University, Karabuk Vocational College, 78050, Karabuk, Turkey
c
Zonguldak Karaelmas University, Karabuk Technical Education Faculty, 78100 Karabuk, Turkey

Received 3 October 2005; accepted 14 July 2006

Available online 22 September 2006

Abstract

In this study, measurement of the chip-back temperature developed during cutting was investigated using an embedded thermocouple
into the cutting tool. AISI 1117 steel was used as the workpiece material and a K type thermocouple was used for the temperature mea-
surement. The cutting tool used was uncoated and without chip braker and in the form of SCMW 12 M508-S2F according to ISO 1832.
This cutting tool was fixed on a tool holder in the form of SSBCR 25 25 M12 and the side cutting edge angle during tests was 75° as
suggested in ISO 3685. The cutting tests were carried out on a Johnford TC35 CNC turning center. In selecting the cutting parameters,
the reference values indicated in ISO 3685 were used. In order to locate the thermocouple on the cutting tool, a Flir Systems Therma Cam
thermal camera was used. The results showed that increasing cutting speed, feed rate and depth of cut resulted in increase in the tem-
perature at the back rake surface. However, cutting speed had the most influence on the temperature.
Ó 2006 Elsevier Ltd. All rights reserved.

Keywords: Temperature; Machining; Thermal camera; Thermocouple method; Cutting parameters

1. Introduction measurement methods, etching methods and the recently

The energy used for plastically deforming the workpiece
material during machining is converted into heat energy.
The temperatures developed during cutting as the result
of heat are mainly dependent on the contact between the
tool and chip, the amount of cutting forces and the friction
between the tool and chip. Almost all the heat energy
developed is transferred into the cutting tool and cut work-
piece material while a portion of it is dissipated through the
chip. The majority of the heat is developed in the shear
zone. For this reason, the contact length between the chip
and the tool has influences on the cutting forces, cutting
conditions of the tool, the tool performance and tool life
[1,2]. Thermocouple method, radiation based temperature
*
Corresponding author. Tel.: +90 312 212 68 20; fax: +90 312 212 00
59.
E-mail address: useker@gazi.edu.tr (U. Seker).
used physical vapour deposition (PVD) methods are the
basic methods used for the temperature measurements dur-
ing machining.
The chip produced during machining of a workpiece acts
to remove the heat from the cutting zone. This heat is pro-
duced as the result of friction. Therefore, the friction between
the tool and the chip needs minimising. Adhering of the chips
between the surfaces is also related to the friction. Increasing
the amount of chip to be removed requires increases in cut-
ting speed, feed rate and depth of cut. To effect this econom-
ically depends on the machining factors of the cutting tool
and workpiece material. These factors are machine tool,
cutting tool, cutting fluid and workpiece material properties.
The heat developed in the workpiece is dissipated from the
cutting zone by four different means; the cutting tool, work-
piece, formed chip and the cutting fluid [1–3].
Fig. 1 shows the heat distribution in the chip and work-
piece material during orthogonal metal cutting. The material

0261-3069/$ - see front matter Ó 2006 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2006.07.009
2330 I. Korkut et al. / Materials and Design 28 (2007) 2329–2335
Fig. 1. Heat distribution in workpiece and chip during orthogonal cutting
[4].
moving in X direction pass through the first deformation
zone. It is seen that the heat developed in this zone increases
until it leaves this zone together with the chip. It is also seen
that the same phenomenon takes place in the Y direction in
the second deformation zone. Therefore, it is understood
that the highest temperature is observed on the cutting tool
surface a bit away from the cutting edge. In Z direction, some
amount of the heat is observed on the workpiece as the result
of heat developed in the first deformation zone. Also, some
amount of heat transferred from the second deformation
zone is concentrated on the cutting tool.
The chip moves very fast as it is close to the cutting tool
surface. Therefore, the chip has more heat carrying capac-
ity than the cutting tool. For this reason, the heat gone into
the cutting tool is generally constitutes only a small portion
of the total heat developed and this can be neglected at very
low cutting speeds [4].
In 1924 Shore in the United States of America and
almost at the same time Gottwein in Germany and in
1926 Herbert in England developed tool-workpiece ther-
mocouple method in order to determine the temperature
across cutting tool rake face [2]. Grzesik investigated the
tool–chip interface at different conditions during machin-
ing of AISI 1045 and AISI 304 steels using uncoated and
coated cemented carbide cutting tools. The measurements
were made using thermocouples embedded in the work-
piece. The cutting forces and the tool–chip contact lengths
were also measured. It was evidenced that tool–chip inter-
face temperature is affected by the thermal conductivity of
the workpiece and the cutting tool. It was also evidenced
that the friction on cutting tool rake face has an significant
influence on the heat developed at around 200 m/min cut-
ting speed [5].
Milikic et al. studied the cutting tool temperatures and
temperature dependent wear mechanisms during machin-
ing of AISI 1730 steel using uncoated and coated carbide
tools. They revealed that the cutting temperatures are
affected by the cutting parameters like cutting speed and
feed rate. It was also found that the coated carbide tools
give rise to higher cutting temperatures than the uncoated
ones [6].
The radiation based methods used for the measure-
ments of cutting tool, chip and workpiece temperatures
are practical but these methods are very complex and only
suitable for laboratory conditions. Although, temperature
measurements using temperature sensitive paints are very
practical and cost effective, they are limited to very good
controlled heating conditions. As the heating rate and
duration are important, they are affected by rapid temper-
ature changes of the cutting tools and results in series
errors.
Most of the methods are related with tool–chip interface
and for this reason the thermocouple method used most
widely for the tool studies. For measurement of the temper-
ature during machining, the tool-workpiece thermocouple
method can be used effectively provided it is calibrated
accurately and the cutting time is short [7–12].
Although the embedded thermocouple method is a diffi-
cult method to be implemented for temperature measure-
ment, the momentary changes in heat during machining
can be determined. These changes occurs mainly due to
the friction. This method requires high accuracy and is time
consuming. Also, placement of the thermocouples into the
holes is another disadvantage of this method.
In this study, the most widely used embedded thermo-
couple method was selected for measurement of the tem-
perature during machining as this method is good at
determining the temperature distribution on the cutting
tool and the momentary changes in heat in a best way. This
method is also useful and reliable. In order to measure the
temperature of the chip-back surface which is in contact
with the tool rake face, a test set-up was developed. This
set-up was connected to a computer using the necessary
hardware and software for data acquisition. The relation-
ship between the chip-back surface temperature and the
cutting parameters is examined.
2. Materials and method
2.1. Test specimens
AISI 1117 steel was used as the worpiece material. These workpieces
were 400 mm in length and 60 mm in diameter. Prior to the temperature
measurement tests, the surfaces of these workpieces were machined at
1 mm depth of cut on a conventional lathe in order remove any inclusions,
scale and possible hardened layer. AISI 1117 steel is widely used in indus-
try and its chemical composition is given in Table 1.
2.2. Cutting tool and machine tool
The cutting tool used was cemented carbide. Cemented carbide cutting
tools are used for machining steel as they are highly wear resistant at high
cutting speed and widely used for machining steels. The cutting tool was in
SCMW 12M508-S2F form according to ISO 1832 and produced by Stell-
ram without chip breaker. This cutting tool had 0° rake angle and 7° relief
angle. According to ISO designation, its grade was somewhere between
 I. Korkut et al. / Materials and Design 28 (2007) 2329–2335 2331

Table 1
Chemical composition of the test specimen
C Si Mn P S Cr Mo Ni Al Co
0.114 0.004 1.48 0.076 0.382 0.098 0.0270 0.345 0.011 0.003
Cu Nb Ti V W Pb Sn Sb Fe
0.065 0.002 0.001 0.001 0.037 0.002 0.0340 0.002 97.34

P10 and P20. The cutting tool was fixed on a rigid tool holder in the form
of SSBCR 2525M1. This tool holder provided a 75° side cutting edge angle
as suggested in ISO 3685. The machining tests were carried out on a John-
ford TC35 CNC turning center.
2.3. Thermocouple
For temperature measurement, a mineral isolated K type thermocou-
ple was used whose diameter was 1.5 mm and length 50 mm. The edges
of the thermocouple wires were welded to each other to form the hot
junction. After the welding process, (+) and ( ) polarities were isolated
from each other using a mineral isolation material. Then, Inconel 600
was used as the protective cover for the isolated thermocouple. The func-
tion of this cover was to protect the thermocouple against any mechan-
ical impact and any chemical and physical wear. In order to effect the
connection between the thermocouple and the device and to obtain the
measured temperatures without any loss, a special thermocouple com-
pensation cable was used.
2.4. Selection of cutting parameters
When selecting the cutting parameters, the cutting tool manufacturer’s
suggestions for feed rate (0.08–0.5 mm/rev) and cutting speed (100–200 m/
min) were taken into consideration. Five different cutting speeds were
selected as suggested in ISO 3685. Similarly, the depth of cut value was
also determined in accordance with ISO 3685 for 0.8 mm cutting tool nose
radius [13].
The cutting parameters used for the tests are given in Table 2. In order
to effect the same conditions for all the tests, only one cutting edge of a
cutting tool was used for each test. A total of 50 tests were performed
by changing the cutting speed, feed rate and depth of cut values.
2.5. Construction of test set-up
In order to measure the chip-back surface temperature, a hole which is
a bit away from the cutting edge should be formed on the cutting tool and
a thermocouple should be inserted into this hole. The difficulty in deter-
mining the place of this hole is one of the most important disadvantages
of embedded thermocouple method. That is because, the tool–chip contact
point changes continuously during cutting as the results of changes in cut-
ting speed, feed rate and depth of cut [5,6,8–11]. The work carried out by
Trent was taken as reference when defining the place of the hole on the
cutting tool [14]. Additionally, a Flir Systems Therma Cam thermal cam-
era was also used to verify this place during the tests (Fig. 2). The highest
temperature value was observed for the tool which had a hole 1.5 mm
away from the cutting edge. Both of the methods were compared and it
was decided that the thermocouples should be placed 1.5 mm away from
the cutting edges. For this purpose, the cutting tools were drilled from side
to side.

Table 2
Testing cutting parameters used for the tests
Cutting speed, V (m/min) Feed rate, f (mm/rev) Experiment no. Depth of cut, a (mm) Experiment no. Feed rate, Depth of cut,
f (mm/dev) a (mm)
50 0.10 1 1 26 0.10 2
0.15 2 27 0.15
0.20 3 28 0.20
0.25 4 29 0.25
0.30 5 30 0.30
75 0.10 6 1 31 0.10 2
0.15 7 32 0.15
0.20 8 33 0.20
0.25 9 34 0.25
0.30 10 35 0.30
100 0.10 11 1 36 0.10 2
0.15 12 37 0.15
0.20 13 38 0.20
0.25 14 39 0.25
0.30 15 40 0.30
125 0.10 16 1 41 0.10 2
0.15 17 42 0.15
0.20 18 43 0.20
0.25 19 44 0.25
0.30 20 45 0.30
150 0.10 21 1 46 0.10 2
0.15 22 47 0.15
0.20 23 48 0.20
0.25 24 49 0.25
0.30 25 50 0.30
2332 I. Korkut et al. / Materials and Design 28 (2007) 2329–2335
Fig. 2. Thermal camera view.
Fig. 3. Experimental set up.
The thermocouples were placed into the predrilled holes on the tool
holder and the cutting tool (Fig. 3) and glued with a special material in
order to fix them.
The ends of the thermocouples were connected to an Advantech PLCD
8710 terminal board using a special thermocouple cable. An Advantech
PCI 1710 HG data acquisition and control card was also mounted to
the terminal board.
3. Experimental results and discussion
The measured chip-back surface temperatures depen-
dent on the cutting parameters are given in Fig. 4. The
average temperatures for each cutting speed, feed rate
and depth of cut were determined by taking into consider-
ation the values which were between the starting and end-
ing points of time dependent cutting tool temperatures.
Changes in the temperature of the cutting tool were exam-
ined depending on the cutting speed, feed rate and depth of
cut.
Fig. 4. Time dependent measured temperature variation.
Table 3 also shows the average chip-back surface tem-
peratures measured when machining with uncoated cutting
tool at five different cutting speeds, five different feed rates
and two different depths of cuts.
Based on the experimental results listed in Table 3, feed
rate dependent changes of the average cutting temperature
is shown in Fig. 5 for five different cutting speeds.
The graphs in Fig. 5 show that the temperature increases
with increasing cutting speed and feed rate. The same
graphs also show that the cutting speed has a much more
influence on the temperature than the feed rate. This find-
ings are in agreement with the previous studies [2,4,14].
When the five different cutting speeds were taken into
consideration, the cutting speed increases by 25% and
33% at each step. However, the increase in the cutting tem-
peratures with increasing cutting speed is not stable and
was found to change between 3% and 35%. This situation
indicates that the cutting speed has an important influence
on the cutting temperatures developed during machining.
At the low cutting speeds (50 and 75 m/min), increases
in the cutting speed resulted in 9–24% increases in the
temperatures while at high cutting speeds (125 and
150 m/min), increases in the cutting speed resulted in only
little changes (3–10%) in the temperatures. This situation
indicates that the energy required for the plastic deforma-
tion of the workpiece reaches to a sufficient level at the
higher cutting. Therefore, the required energy for the fur-
ther plastic deformation decreases with the further increase
in the cutting speed and the heat developed in the deforma-
tion zone decreases.
When the cutting speed was increased to 100 m/min
from 75 m/min, a reduction of about 3–10% in the temper-
atures was observed at the different feed rates. This can be
attributed to the decrease in the tool–chip contact length
and this situation, in turn, results in less friction forces.
This makes the flow of the chip easy.
As can be seen from Fig. 6, the feed rate values deter-
mined in accordance with ISO 3685 increase by 33% or
50% at each step. However, increases in the chip-back sur-
face temperatures with increasing feed rate were not steady
and are between 1% and 10%. This situation indicates that
feed rate has a less influence on the temperatures developed
during machining and also indicates that increasing feed
rate leads to a stable trend in the temperature.
 I. Korkut et al. / Materials and Design 28 (2007) 2329–2335 2333

Table 3
The average temperatures obtained for different cutting speeds, feed rates and depths of cuts
Cutting speed, Feed rate, Experiment no. Depth of cut, Avarage Experiment no. Depth of cut, Avarage temperature (°C)
V (m/min) f (mm/rev) a ( mm ) temperature (°C) a (mm )
50 0.1 1 1 107 26 2 180
0.15 2 130 27 215
0.20 3 138 28 250
0.25 4 158 29 268
0.3 5 169 30 293
75 0.1 6 1 130 31 2 205
0.15 7 148 32 217
0.20 8 160 33 228
0.25 9 165 34 240
0.3 10 185 35 252
100 0.1 11 1 125 36 2 188
0.15 12 140 37 217
0.20 13 155 38 231
0.25 14 166 39 244
0.3 15 187 40 263
125 0.1 16 1 160 41 2 194
0.15 17 165 42 226
0.20 18 178 43 236
0.25 19 185 44 258
0.3 20 207 45 276
150 0.1 21 1 169 46 2 205
0.15 22 176 47 238
0.20 23 187 48 256
0.25 24 196 49 271
0.3 25 217 50 302

Fig. 5. Chip-back surface temperature variations depending on the cutting

Fig. 7. Chip-back surface temperature variation depending on the cutting
speed at 1 mm depth of cut when machining with uncoated cutting tool.
speed at 2 mm depth of cut when the uncoated tool was used.

2 mm and the cutting speed was 50 m/min, about 50% tem-

Fig. 6. Chip-back surface temperature variation depending on the feed
rate at 1 mm depth of cut when the uncoated tool was used.
When the depth of cut was increased twofold, cutting
speed dependent temperatures increased by between 40%
and 60% (Fig. 7). Especially, when the depth of cut was
perature rise was observed. This can be attributed to con-
version of the increasing mechanical energy to the heat
energy as the energy required for the plastic deformation
of the workpiece does not reach an adequate level. At
low cutting speeds, the shear speed and the chip speed also
decrease. This situation increases the contact time of the
chip when it moves on the rake face of the cutting tool.
This, in turn, increases the temperature in the cutting zone.
The higher temperatures observed at 50 m/min cutting
speed and 0.2, 0.25 and 0.3 mm/rev feed rates are consid-
ered to be the result of built-up edge (BUE) problem
encountered at low cutting speed when machining ductile
materials. Optical microscopy examinations carried out
on the cutting tools revealed the formation of BUE at this
cutting speed. This indicates the problem of machining
ductile materials at lower cutting speeds.
2334 I. Korkut et al. / Materials and Design 28 (2007) 2329–2335
When the cutting speed was increased to 75 m/min from
50 m/min at 2 mm depth of cut, the temperatures were
decreased by between about 10% and 15% for 0.2, 0.25
and 0.3 mm/rev feed rates (Fig. 7). These reductions can
be explained by the elimination of BUE and easy deforma-
tion with increasing cutting speed.
If the temperature changes are examined for different
feed rates, it is seen from Fig. 8 that the temperatures
increase by 10–20% for the different cutting speeds when
the feed rate is increased to 0.15 mm/rev from 0.1 mm/
rev. Further increases in the feed rate lead to an increase
of low order (1–10%) in the temperature.
Young and Chou also measured the chip-back surface
temperatures [15]. The results obtained in this study are
in agreement with their values. As can be seen from
Fig. 9, when the temperatures at the point 1.5 mm away
from the cutting edge and the experimentally obtained
temperatures are examined, it is seen that high tempera-
tures are observed at this point and tool–chip contact
length increases depending on this. Some differences are
seen between the experimentally obtained temperature val-
ues and those in Fig. 9. These differences can be explained
by the different methods used for the temperature measure-
ment. Young and Chou used an infrared technique to mea-
sure the temperatures while an embedded thermocouple
method was used in this study to measure the tempera-
Fig. 8. Chip-back surface temperature variation depending on the feed
rate at 2 mm depth of cut when the uncoated tool was used.
Fig. 9. Chip-back surface temperature distribution throughout the chip
flow axis [15].
tures. It has been proved once again that thermocouple
method is practical and reliable in local temperature
measurement.
In metal cutting operations, the heat which effectively
causes to increase the heat at the area close to the cutting
edge is among the important factors for an acceptable tool
wear process and predetermined tool life. Conversion of
almost all the power used in machining into heat energy is
a factor limiting the performance of the cutting tool. The
temperature reaching very high values at the tool–chip inter-
face as the result of the heat adversely affects the hot hard-
ness of the cutting tool and at the same time activate wear
mechanisms (adhesion, diffusion, thermal fatigue, etc.).
4. Conclusions
In this study, chip-back surface temperature variations
depending on the cutting parameters were examined and
based on the findings the following conclusions can be
drawn:
– When the changes in the temperatures are interpreted
depending on the changes in the cutting speed and depth
of cut, it is seen that the increase in the cutting speed and
the feed rate caused an increase in the temperature and
the cutting speed was found to be an effective parameter
in temperature rise.
– When the cutting parameters (cutting speed, feed rate
and depth of cut) are considered, the cutting speed
and depth of cut were found to be more effective than
the feed rate in the chip-back surface temperature. Espe-
cially, a twofold increase in the depth of cut resulted in
about 40–60% increase in the chip-back surface temper-
ature. A 25% and 50% increases in the cutting speed led
to the increases of between 8% and 35% in the tempera-
tures developed on the cutting tool while 33% and 50%
increases in the feed rate 1–10%.
– At 50 m/min cutting speed and 0.2, 0.25 and 0.3 mm/rev
depths of cuts, built-up edge (BUE) was found to be
effective. BUE is generally seen when machining ductile
materials at low cutting speed with higher cutting tem-
peratures. This highlights the problem of machining
ductile materials at low cutting speeds.
Acknowledgement
The authors would like to acknowledge Gazi University
Scientific Research Projects (07/2002–20) for the financial
support throughout this study.
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