A predictive model for temperature distributions in 'classical' orthogonal cutting

This paper extends the 'unified mechanics of cutting approach' to the prediction of three-dimensional temperature distributions, in addition to predicting forces and power in classical orthogonal cutting operations. The predictive model is based on the modified mechanics of cutting analysis, incorporating the 'edge force', together with a three-dimensional finite difference thermal model for the tool-chip-workpiece system. Significant features of the user-friendly computer-aided thermal model are the inclusion of the 'edge' heat source, and automated grid generation routine with optimum grid densities which satisfy the global energy balance criterion. In addition, the in-built graphics capabilities display the predicted temperature distributions, peaks, and averages. Predictions from the model have been both qualitatively and quantitatively verified by extensive simulation studies and then experimentally verified using the proven tool-work thermocouple technique and with 'state of the art' infrared thermography equipment. Limitations of infrared thermography in machining research are amply demonstrated. This work represents a further step towards the modeling of machining operations for predicting and improving their performance.