Thermal modeling of the metal cutting process - Part II: temperature rise distribution due to frictional heat source at the tool-chip interface

Heat partition and the temperature rise distribution in the moving chip as well as in the stationary tool due to frictional heat source at the chip-to ol interface alone in metal cutting were determined analytically using func tional analysis. An analytical model was developed that incorporates two mo difications to the classical solutions of Jaeger's moving band (for the chi p) and stationary rectangular (for the tool) heat sources for application t o metal cutting. It takes into account appropriate boundaries (besides the tool-chip contact interface) and considers non-uniform distribution of the heat partition fraction along the tool-chip interface for the purpose of ma tching the temperature distribution both on the chip side and the tool side . Using the functional analysis approach, originally proposed by Chao and T rigger (Transactions of ASME, 1951; 73:57-68), a pair of functional express ions for the non-uniform heat partition fraction along the tool-chip interf ace - one for the moving band heat source (for the chip side) and the other for the stationary rectangular heat source (for the tool side) were develo ped. Using this analysis, the temperature rise distribution in the chip and the tool were determined for two cases of machining, namely, conventional machining of steel with a carbide tool at high Peclet number (N-Pe approxim ate to 5-20) and ultraprecision machining of aluminum with a single-crystal diamond tool at low Peclet number (N-Pe-0.5). The calculated temperature r ise distribution curves on the two sides of the tool-chip interface are fou nd to be well matched for both cases. The analytical method developed was f ound to be much faster, easier to use, and more accurate than various numer ical methods used earlier. Further, the model provides a better physical ap preciation of the thermal aspects of the metal cutting process. (C) 2000 El sevier Science Ltd. All rights reserved.