An investigation of the thermal effects in orthogonal cutting associated with multilayer coatings

This paper deals with an experimental and analytical investigation into the tool-chip interface behaviour, influencing the temperature and heat transfer at the multilayered coated-tool rake face during orthogonal cutting of carbon and stainless steels. New methodology for assessing the amount of thermal energy generated when machining with a coated tool insert with natural and restricted contact coupled with a metallic chip, using thermophysical properties of the sliding materials is developed in this study. It was proven, based on the heat flux analysis, that the use of advanced coatings with an intermediate Al2O3 layer can substantially improve the heat flow into the chip at distinctly lower temperatures than other commercially available coatings. The data obtained can be used for the optimization of tool selection with respect to friction and heat transfer and for maintaining the recommended contact temperature.