ME - 535

METAL CUTTING

TEMPERATURES IN METAL
CUTTING
 Primary shear zone
(A-B)
plastic
deformation
Secondary shear
zone (C-B)
friction
Between tool and
workpiece (D-B)
plowing force
(negligible)

METU / ME535 / CH-3 / SPRING’01

 High temperature
- shortens tool life
High
- causestemperature:
thermal distortion
- causes dimensional changes in the
work piece,
-making control of dimensional
accuracy difficult

To use coolant is an efficient method to

reduce the cutting zone temperature

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 HEAT GENERATION IN METAL CUTTING

Energy consumption (or heat generated) during machining Pm :

Fc : cutting force
Pm = Fc V V : cutting speed
Ps : heat generated in primary shear zone
Pm = Ps + Pf Pf : heat generated in secondary shear zone
Ff : friction force
Pf = Ff V0 V0 : velocity of chip flow

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 3. HEAT TRANSFER IN A MOVING MATERIAL

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 Heat transfer across AB

  1  
k y  cv   y y
x  2 y 
Heat transfer across CD

     1  1  
k    x y  cv   x  y y
x  x   2 x 2 y 

Heat transfer across AD


k x
y
Heat transfer across BC

   
k    y x
y  y 

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 Net heat flow into the element = 0

QAB + QAD = QCD + QBC

Therefore  2  2 R 
 2 0
; y 2
x a x

R, thermal number=
v : cutting speed
ac: undeformed chip
thickness

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 TEMPERATURE DISTRIBUTION IN METAL CUTTING

Temperature distribution in workpiece and tool during orthogonal cutting (V=2.5m/s ,

HSS tool)

METU / ME535 / CH-3 / SPRING’01

 Heat generated during cutting is distributed among chip, workpiece and tool

Pm = Qc + Qw + Qt

Pm : total rate of heat generation

Qc : rate of heat transportation by the chip
Qw : rate of heat conduction into the
workpiece
Qt : rate of heat conduction into the tool

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 Pm = Qc + Qw + Qt
Qt has usually very small proportion in Pm . Except at very low
cutting speeds, it may be neglected.

The maximum temperature in the tool/chip interface area is almost

in the middle of the tool/chip contact length.

Particular temperature distribution depends on specific heat and

thermal conductivity of tool work pair materials, cutting conditions
such as cutting speed, feed, depth of cut and type of cutting fluid.

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 TEMPERATURES IN THE PRIMARY
SHEAR ZONE

(1   )Ps  scva c a w
volume
energy flow
generated
energy carried
away
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 TEMPERATURES IN THE PRIMARY SHEAR ZONE

Or,
s 
1   Ps
cva c a w
where
Ps : heat generation in primary shear zone
Γ : portion of Ps which is conducted to the workpiece, so,
this portion will not cause temperature increase in chip
θs : average temperature rise in primary shear zone
C : specific heat
ρ : density
v : cutting speed
ac : undeformed chip thickness
aw : depth of cut

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 The idealized model of the cutting
process defined by Weiner and
Rapier:

METU / ME535 / CH-3 / SPRING’01

 Weiner assumed that no heat was conducted in the
material in the direction of its motion and simplified the
heat transfer equation to:
 2 R 
 0
y 2
a x

The following figure shows the theoretical solution of

Weiner and experimental work of Nakayama for
expressing the relationship between Γ and RtanΦ.

R, thermal number =

It can be seen that the theory has slightly underestimated

Γ at high values of RtanΦ (i.e., at high speeds and high
feeds) due to the plane heat source assumption.

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 Г

R tanf

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 TEMPERATURES IN THE SECONDARY SHEAR ZONE (Friction
Zone)
Rapier assumed that the heat zone resulting from friction
between chip and tool is a plane heat source when solving the
Equation 3.6.

  R 
2
 0
y 2
a x

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 The following expression was obtained.

θm R
 1.13
f l0
where

θf : average temperature rise in chip due to frictional heating

θm : maximum temperature rise in chip due to frictional
heating

This result does not agree with the experimental observations

(given in the next page).

Equation overestimates θm. The reason is that the heat

generation does not take place in a plane .

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 θm/θf

W0

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 Pf   f cva c a w
heat generated heat carried away
in friction zone from friction zone
Pf
f 
cva c a w
Finally, the maximum temperature in chip can be obtained by:

θmax = θm + θs + θ0
where
θm : maximum temperature rise in chip due to
frictional heating
θs : average temperature rise in primary shear zone
θ0 : initial temperature of the workpiece

METU / ME535 / CH-3 / SPRING’01

 EFFECT OF CUTTING SPEED ON TEMPERATURE

If cutting speed increases, heat generation increases.

Increase in heat generation causes temperature increase only

where the heat transfer does not increase by higher speed, i.e.,
at tool face.
T (C)

V (m/s)

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EXAMPLE
Orthogonal cutting of mild steel
Working normal rake angle gne = 0o
Cutting force Fc = 890 [N]
Thrust force Ft= 667 [N]
Cutting speed V = 2 [m/s]
Undeformed chip thickness ac = 0.25 [mm]
Width of the cut ap = 2.5 [mm]
Cutting ratio rc = 0.3
Length of contact between chip and tool lf = 0.75 [mm]

Find the maximum chip-tool temperature.

21
Pm = Fc V = 890 x 2 = 1780 [J/s]
Pf = Ff V0 = Ff v rc
If gne = 0o then Ff = Ft then Pf = Ft V rc
Pf = 667 x 2 x 0.3 =400 [J/s]
Ps = Pm – Pf = 1380 [J/s]
In order to estimate , the value of Rtanf is required.
R = ( c v ac)/k and tanf  {rc cosgne/(1-rc singne)}
and when gne = 0 then tanf  rc

22
For mild steel, assume the followings:
 = 7200 [kg/m3]
k = 43.6 [J/s m oK]
c = 502 [J/kg oK]
R= (7200 [kg/m3] x 502 [J/kgoK] x 2 [m/s] x 0.00025 [m])/(43.6 [J/s m oK])

R = 41.5
R tanf = 41.3 x 03 = 12.45

23
 Г

R tanf

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   0.1
s = (1-) Ps/( c v ac aw)
s = {(1-0.1) x 1380}/(7200 x 502 x 2 x 0.00025 x 0.0025)
s = 275 oC mean temp rise across shear plane

By neglecting the heat transfer to the cutting tool, then

f = {400}/(7200 x 502 x 2 x 0.00025 x 0.0025)
f =88.5 oC mean temp rise in secondary shear zone
 Assume that w0 = 0.2 for mild steel
l0 = lf/a0 = (lf rc)/ac = (0.75 x 0.3)/0.25 = 0.9
(R/l0) = 41.5/0.9 = 46.1
 θm/θf

W0

For (R/l0) = 46.1 m/f = 4.2

m = 4.2 x 88.5 = 372 oC
max = m + s+ 0 = 372 + 88.5 + 22
max = 669 oC
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 MEASUREMENT OF CUTTING TEMPERATURE

1. Work Tool Thermocouple

- Most widely used

- Limited since it can not give the temperature distribution on

chip-tool interface

- Calibration is needed for each tool/workpiece combination

- Calibration of stationary tool may not give the same values

during cutting

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 MEASUREMENT OF CUTTING TEMPERATURE

Work Tool Thermocouple measurement technique

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 MEASUREMENT OF CUTTING TEMPERATURE

2. Direct Thermocouple Measurements

i. Nakayama technique (see figure below)
ii. Thermocouple inserted on tool shank to measure insert
temperature

Nakayama cutting temperature measurement technique

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 MEASUREMENT OF CUTTING TEMPERATURE

3. Infrared Radiation

Suitable for determining of temperature distribution in the

cutting zone

i. Radiation pyrometer method

ii. Infrared photograph of cutting operation
iii. Thermal imaging camera, an improved method for infrared
radiation

4. Others

i. Calorimetric techniques
ii. Temperature-sensitive chemicals

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