Thermal modeling of the metal cutting process - Part III: temperature risedistribution due to the combined effects of shear plane heat source and the tool-chip interface frictional heat source

This paper is Part III of a 3-part series on the Thermal Modeling of the Me tal Cutting Process. In Part I (Komanduri, Hou, International Journal of Me chanical Sciences 2000,42(9):1715-1752), the temperature rise distribution in the workmaterial and the chip due to shear plane heat source alone was p resented using modified Hahn's moving oblique band heat source solution wit h appropriate image sources for the shear plane (Hahn, Proceedings of the F irst US National Congress of Applied Mechanics 1951. p. 661-6). In Part II (Komanduri, Hou, International Journal of Mechanical Sciences 2000,43(1):57 -88), the temperature rise distribution due to the frictional heat source a t the tool-chip interface alone is considered using the modified Jaeger's m oving-band (in the chip) and stationary rectangular (in the tool) heat sour ce solutions (Jaeger, Proceedings of the Royal Society of New SouthWales, 1 942;76:203-24; Carlsaw, Jaeger. Conduction of heat in solids, Oxford, UK: O xford University Press, 1959) with appropriate image sources and non-unifor m distribution of heat intensity. The matching of the temperature rise dist ribution at the tool-chip contact interface for a moving-band (chip) and a stationary rectangular heat source (tool) was accomplished using functional analysis technique, originally proposed by Chao and Trigger (Transactions of ASME 1955,75:1107-21). This paper (Part III) deals with the temperature rise distribution in metal cutting due to the combined effect of shear plan e heat source in the primary shear zone and frictional heat source at the t ool-chip interface. The basic approach is similar to that presented in Part s I and II. The model was applied to two cases of metal cutting, namely, co nventional machining of steel with a carbide tool at high Peclet numbers ( approximate to 5-20) using data from Chao and Trigger (Transactions of ASME 1955;75:1107-21) and ultraprecision machining of aluminum using a single-c rystal diamond at low Peclet numbers ( approximate to 0.5) using data from Ueda et al. (Annals of CIRP1998;47(1):41-4). The analytical results were fo und to be in good agreement with the experimental results, thus validating the model. Using relevant computer programs developed for the analytical so lutions, the computation of the temperature rise distributions in the workm aterial, the chip, and the tool were found. The analytical method mas found to be much easier, faster, and more accurate to use than the numerical met hods used (e.g., Dutt, Brewer, International Journal of Production Research 1964:4:91-114; Tay, Stevenson, de Vahl Davis, Proceedings of the Instituti on of Mechanical Engineers (London) 1974;188:627). The analytical model als o provides a better physical understanding of the thermal process in metal cutting. (C) 2000 Elsevier Science Ltd. All rights reserved.