Finite element analysis of temperature rise in metal cutting processes

The heat generation during metal cutting processes affects material’s properties and strongly influences the cutting forces and tool wear. Knowledge of the ways in which the cutting conditions, tool geometry and tool material effect the temperature distribution is essential for the study of thermal effects on tool life. A finite element based computational model is developed to determine the temperature distribution in a metal cutting process. The model is based on multi-dimensional steady state heat diffusion equation along with heat losses by convection film coefficients at the surfaces. The models for heat generations within primary and secondary zones, and in the rake face due to friction at the tool–chip interface are discussed and incorporated in the FEM model. Results are presented for the machining of high-speed carbon steel and for a range of cutting conditions.