Lecture 5 Heat Generation in Metal Cutting Operations

LECTURE 5: HEAT GENERATION IN
METAL CUTTING OPERATIONS
11/23/2023 Eng. Ngilangwa, J.L. (ME 8305 LECTURE NOTES 1

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Introduction
• While machining operation is performed, a large
amount of heat is generated from the cutting
point at three different points which are:
1.Heat generation at the shear plane
2.Heat generation at tool chip interface
3.Heat generation at tool work interface

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Cutting Temperatures
Of the total energy consumed in machining, nearly
all of it is converted into heat. The heat generated
can cause temperatures to be as high as 6000C at
tool chip interface.
1) Elastic deformation- Energy required for the
operation is stored in the material as strain
energy and no heat is generated.
2) Plastic deformation – Most of the energy used
is converted as heat
Cutting temperature has a controlling influence on
the rate of tool wear and friction between tool and
chip.
)
Cutting temperatures are important to
be known because, high temperatures,
1.Reduce tool life.
2.Produce hot chips that pose safety
hazards to the machine operator.
3.Can cause inaccuracies in work
part dimensions due to thermal
expansion of work piece material.

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The effect of cutting temperature,
particularly when it is high is mostly
detrimental to both the tool and the job.
The major portion of the heat is taken away
by the chips. But it does not matter because
chips are thrown out.
So attempts should be made such that the
chips take away more and more amount of
heat leaving small amount of heat to harm
the tool the job and the operator.

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Effect of cutting temperature on tool
The possible detrimental effects of the high
cutting temperature on cutting tool (edge)
are:
 Rapid tool wear which reduces tool life
 plastic deformation of the cutting edges
if the tool material is not enough hot-
hard and hot-strong
 thermal flaking and fracturing of the
cutting edges due to thermal shocks.
 Built up Edge formation from some of
the materials.
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Effect of cutting temperature on Job
The possible detrimental effects of the high
cutting temperature on machined job are:
 Dimensional inaccuracy of the job due
to thermal distortion and expansion-
contraction during and after machining
 surface damage by oxidation, rapid
corrosion, burning etc.
 induction of tensile residual stresses
and micro cracks at the surface /
subsurface.
)
•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, τs 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.
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Effects of Heat Generation in Metal Cutting
There are the following effects that occurred during heat
generation in metal cutting.
i. Rapid tool wear and decreases tool life.
ii. Cutting edge plastically deforms and Loss of hot
hardness.
iii. Thermal flaking and fracturing of cutting edge.
iv. Built-up edge formation.
v. Dimensional inaccuracy due to thermal expansion of
workpiece.
vi. The surface of work may damage due to oxidation and
burning.
vii. Micro cracks at the work surface so the physical
properties of a workpiece may change.
viii.Residual stress can be developed.
ix. Operator hazards.
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Control of Heat Generation in Metal Cutting
Most heat generation in metal cutting
occurred when continuous chips are
formed to avoid this chip breakers are
used.
Apart from this, heat generation can be
controlled by adopting the following
methods.
i. Proper selection of tool material.
ii. Proper selection of tool geometry.
iii. Optimum cutting speed.
iv. Selection of cutting fluid.
v. Application of special technique.
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Sources and Causes of heat generation in
Machining
During machining, heat is generated at the cutting point from
three sources, as indicated in Figure below.
(i) Primary shear zone
(ii) Secondary deformation zone
(iii) worn out flanks

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Sources of heat generation in Machining Cont…
Those sources and causes of development
of cutting temperature are:
 Primary shear zone (i) where the major
part of the energy is converted into heat.
 Secondary deformation zone (ii) at the
chip – tool interface where further heat
is generated due to rubbing and / or
shear.
 At the worn out flanks (iii) due to
rubbing between the tool and the
finished surfaces.
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Temperature distribution in Metal Cutting

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Temperature distribution in Metal Cutting…
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11/23/2023 Eng. Ngilangwa, J.L. (ME 8305 LECTURE NOTES
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There are three main sources of heat in metal cutting. (1) Primary shear zone. (2)
Secondary shear zone tool–chip (T–C) interface. (3) Tool flank. The peak temperature
occurs at the center of the interface, in the shaded region.
Eng. Ngilangwa, J.L. (ME 8305 LECTURE
11/23/2023 19
NOTES)
11/23/2023 20
NOTES)
Distribution of
heat generated in
machining to
the chip, tool, and
workpiece.
Heat going to the
environment
is not shown.

11/23/2023 21
NOTES)
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The typical relationship of temperature at the tool–chip interface to cutting speed shows a rapid increase.
Correspondingly, the tool wears at the interface rapidly with increased temperature, often created by
increased speed.

11/23/2023 23
NOTES)
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Factors Affecting Temperature

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Cutting Temperatures Cont..
High cutting temperatures
1. Reduce tool life
2. Produce hot chips that pose safety
26
hazards to the machine operator
3. Can cause inaccuracies in part dimensions
due to thermal expansion of work
material

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Analytical methods to compute Cutting Temperatures
Cook’s Method
0.333
0.4U Vt0 
T 
Where, C  K 
δT = Mean temperature rise at tool chip interface, C0
U = Specific Energy in the operation, N-m/mm3
V = Cutting Speed, m/s
t0 = Chip thickness before the cut, m
ρC = Volumetric Specific heat of work material, J/mm3-C0
K = Thermal diffusivity of the work material, m2/s

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Cutting Temperature Cont..
• Derived by Nathan Cook from dimensional analysis using
experimental data for various work materials
0.333 0.333
0.4U  vt o  0.4 Fc  vto 
T      
C  K  C  f  d  K 
where T = temperature rise at tool‑chip interface;

U = specific energy
v = cutting speed;
to = chip thickness before cut;
C = volumetric specific heat of work material;
K = thermal diffusivity of work material ,m2/s
Fc =Cutting force
f = feed
d = depth of cut
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Ken Trigger Cutting Temperature
• Experimental methods can be used to measure
temperatures in machining
• Most frequently used technique is the tool‑chip
thermocouple
29
• Using this method, Ken Trigger determined the
speed‑temperature relationship to be of the form:
T = K vm
where T = measured tool‑chip interface temperature,
K = Thermal diffusivity of the work material, m2/s
v = cutting speed

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Measurement of tool-chip interface temperature

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Effects of Temperature and Friction
• Heat created
• Plastic deformation occurring in metal during process of
forming chip
• Friction created by chips sliding along cutting-tool face
• Cutting temperature varies with each metal and

increases with cutting speed and rate of metal removal

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Effects of Temperature and Friction
• Temperature of metal immediately ahead of cutting tool
comes close to melting temperature of metal being cut.
• Greatest heat generated when ductile material of high
tensile strength is cut.
• Lowest heat generated when soft material of low tensile
strength is cut.
• Maximum temperature attained during cutting action affects
cutting-tool life, quality of surface finish, rate of production and
accuracy of work piece.

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Friction
• Kept low as possible for efficient cutting action
• Increasing coefficient of friction gives greater possibility
of built-up edge forming
• Larger built-up edge, more friction
• Results in breakdown of cutting edge and poor surface finish
• Can reduce friction at chip-tool interface and help
maintain efficient cutting temperatures if use good
supply of cutting fluid.

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Conclusion
Heat has critical influences on machining.
• To some extent, it can increase tool wear and then
reduce tool life, get rise to thermal deformation and
cause to environmental problems, etc.
• But due to the complexity of machining mechanics,
it's hard to predict the intensity and distribution of
the heat sources in an individual machining
operation. Especially, because the properties of
materials used in machining vary with temperature,
the mechanical process and the thermal dynamic
process are tightly coupled together.
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Questions:
1) In a turning operation on stainless
steel with hardness = 200 HB, the
cutting speed = 200 m/min, feed =
0.25 mm/rev, and depth of cut =
7.5 mm. How much power will the
lathe draw in performing this
operation if it’s mechanical
efficiency = 90%. When, U = 2.8 N-
m/mm3 = 2.8 J/mm3. [19.44 kW]

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THANK YOU!!!

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LECTURE 5: HEAT GENERATION IN

METAL CUTTING OPERATIONS

11/23/2023 Eng. Ngilangwa, J.L. (ME 8305 LECTURE NOTES 1

11/23/2023 Eng. Ngilangwa, J.L. (ME 8305 LECTURE NOTES 2

11/23/2023 Eng. Ngilangwa, J.L. (ME 8305 LECTURE NOTES 7

11/23/2023 Eng. Ngilangwa, J.L. (ME 8305 LECTURE NOTES 8

(i) Primary shear zone

(ii) Secondary deformation zone

(iii) worn out flanks

11/23/2023 Eng. Ngilangwa, J.L. (ME 8305 LECTURE NOTES 14

11/23/2023 Eng. Ngilangwa, J.L. (ME 8305 LECTURE NOTES 17

Eng. Ngilangwa, J.L. (ME 8305 LECTURE

Eng. Ngilangwa, J.L. (ME 8305 LECTURE

11/23/2023 Eng. Ngilangwa, J.L. (ME 8305 LECTURE NOTES 25

11/23/2023 Eng. Ngilangwa, J.L. (ME 8305 LECTURE NOTES

11/23/2023 Eng. Ngilangwa, J.L. (ME 8305 LECTURE NOTES 27

where T = temperature rise at tool‑chip interface;

11/23/2023 Eng. Ngilangwa, J.L. (ME 8305 LECTURE NOTES

11/23/2023 Eng. Ngilangwa, J.L. (ME 8305 LECTURE NOTES 30

• Friction created by chips sliding along cutting-tool face

• Cutting temperature varies with each metal and

11/23/2023 Eng. Ngilangwa, J.L. (ME 8305 LECTURE NOTES 31

11/23/2023 Eng. Ngilangwa, J.L. (ME 8305 LECTURE NOTES 32

11/23/2023 Eng. Ngilangwa, J.L. (ME 8305 LECTURE NOTES 33

11/23/2023 Eng. Ngilangwa, J.L. (ME 8305 LECTURE NOTES 35

11/23/2023 Eng. Ngilangwa, J.L. (ME 8305 LECTURE NOTES 36

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