Boundary element method analysis of temperature fields in coated cutting tools

Two general boundary element techniques are developed for determining the t emperature fields in materials containing thin coatings. The first method u tilizes a two-dimensional multi-domain approach that is accurate over a wid e range of coating thicknesses. The second technique, which is based on a m ore computationally efficient single-layer approximation, is geared towards applications where the coating thickness is very small. After initially be ing verified with two simplified test cases, both methods are used to deter mine the temperature fields of coated and uncoated metal cutting tool inser ts. Through generation of results for different coating materials (TiN, TiC , and Al2O3) and by comparison with actual experimental data, the accuracy and applicability of the single-domain approximation and multiple-domain me thods are discussed as related to machining processes. (C) 2001 Elsevier Sc ience Ltd. All rights reserved.