Applied Thermal Engineering 25 (2005) 21522168

www.elsevier.com/locate/apthermeng

Finite element analysis of temperature rise in metal cutting

processes
Pradip Majumdar *, R. Jayaramachandran, S. Ganesan
Department of Mechanical Engineering, Northern Illinois University, DeKalb, IL 60115, United States
Received 3 November 2003; accepted 13 January 2005
Available online 19 March 2005

Abstract
The heat generation during metal cutting processes aects materials properties and strongly inuences
the cutting forces and tool wear. Knowledge of the ways in which the cutting conditions, tool geometry and
tool material eect the temperature distribution is essential for the study of thermal eects on tool life. A
nite 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 diusion equation along with
heat losses by convection lm coecients at the surfaces. The models for heat generations within primary
and secondary zones, and in the rake face due to friction at the toolchip 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.

2005 Elsevier Ltd. All rights reserved.
Keywords: Metal cutting; Thermal analysis; Finite element analysis; Heat transfer

1. Introduction
The power consumed in metal cutting is largely converted into heat near the cutting edge of
the tool, and many of the economic and technical problems of machining are caused directly or
*

Corresponding author.
E-mail address: majumdar@ceet.niu.edu (P. Majumdar).

1359-4311/$ - see front matter
2005 Elsevier Ltd. All rights reserved.
doi:10.1016/j.applthermaleng.2005.01.006

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Nomenclature
b
q
c
c_
a
d
/
e
s
e_
r
ql
sx
Ff
H
h
hc
k
L1
L2
Q
qS
qP
T/
t1
t2
tp
Ts
U
VS
Vx
w1

clearance angle, deg

density of the material, kg/m3
maximum shear strain
maximum shear strain rate, s
1
rake angle, deg
ratio of thickness of secondary zone to the chip thickness
shear angle, deg
shear strain
shear stress, N/m2
uniaxial strain rate, s
1
uniaxial stress, N/m2
density of saturated liquid, kg/m3
shear stress at a distance x from the tool edge, N/m2
frictional force along the interface
contact length, mm
distance from the tip along the interface
convection heat transfer coecient, W/m2 K
thermal conductivity of the material
length of cut, mm
chip length, mm
heat generation per unit volume, W/m3
frictional heat generation rate per unit area, W/m2
primary heat generation rate per unit volume, W/m3
ambient temperature, K
depth of cut, mm
chip thickness, mm
plastic zone thickness, mm
surface temperature, K
cutting speed, m/s
sliding velocity, m/s
material velocity at a point, m/s
width of cut, mm

indirectly by this heating action. The cost of machining is very strongly dependent on the rate of
metal removal, and may be reduced by increasing the cutting speed and/or the feed rate, but
there are limits to the speed and feed above which the life of the tool is shortened excessively.
With the higher melting point metals and alloys such as, steel and cast iron, the tools are heated
to high temperatures as metal removal rate increases, and above certain critical speeds, the tools
tend to collapse after a very short cutting time under the inuence of stress and temperature.
The major wear mechanisms that have a dominant inuence on the tool life are adhesive wear,

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abrasive wear, plastic deformation, brittle wear and diusion wear. Adhesive wear, abrasive
wear and plastic deformation wear processes are enhanced by elevated temperature as the heat
generated during cutting thermally weakens materials. Past studies show that main wear mechanisms are diusion and plastic deformation, which depend critically on temperature. Trigger
and Chao [17] have reported empirical models, which can determine tool life, and wear based
on the toolchip interface temperature. They presented an analysis of tool-wear data in terms
of fundamental variables namely, average interface temperature, top face wear and chip
thickness ratio. It is therefore, important to understand the factors that inuence the generation
of heat, the dissipation of heat and the temperature distribution in the tool and work material
near the tool edge. Knowledge of the ways in which the cutting conditions, tool geometry and
material aect this temperature distribution is helpful in arriving at suitable operating
conditions.
There exist various analytical and nite element analyses of heat conduction with moving or
stationary heat sources together with kinematic, geometric and energetic aspects of the metal
cutting process. The widely used analytical model of Loewen and Shaw [8] for orthogonal
machining is based on the superposition of two planar heat sources, one at the shear plane
and the other at the chiptool interface. At the shear plane, the temperature solution for the
workpiece side is obtained by approximating the shear plane as a band heat source moving
on the surface of a stationary semi-innite solid at the shear velocity inclined at the shear angle
to the cutting velocity. The remainder of the shearing energy not entering the workpiece is assumed to cause uniform heating of the chip. The partitioning of the total shearing energy between the workpiece and the chip may be obtained by equating the temperature along the
shear plane from the workpiece side to that from the chip side. Thus, the average shear plane
temperature is calculated by substituting the appropriate portion of the total shearing energy
into either temperature solution. A similar procedure is also adopted to calculate the temperature at the chiptool interface.
The models developed to date have assumed that most of the energy of deformation is converted into heat, and that only a negligible amount is stored as latent energy in the deformed metal. Bever et al. [1] have reported experimental data, which supports this theory. In their
experimental setup chips of goldsilver alloy were made by orthogonal cutting conditions, and
chip geometry and the cutting forces were determined. From these data the stresses and strains
and the shear and friction energies were calculated. The energy stored in chips was determined
as the dierence in the heat eects associated with a sample of cold worked chips and of annealed
chips using an isothermal calorimeter.
In the analytical models, it is often assumed that the chip is formed instantaneously at the shear
plane, so that a uniform plane heat source and velocity discontinuity may be assumed to exist
there. The secondary deformation zone has usually been neglected and the chiptool frictional
heat source is typically assumed to be uniform. Radulescu and Kapoor [11] developed an analytical model for the prediction tool temperature during continuous and interrupted cutting. The
temperature model was based on three-dimensional quasi steady state heat ux model, which assumes that the heat is generated in a parallelepiped shaped chip formation zone and using a time
dependent toolchip and workchip interface temperatures. This heat ux model determines the
amount of heat entering the tool and the workpiece. Based on these heat uxes, the toolchip and
workchip interface temperatures are evaluated separately using a three-dimensional unsteady

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2155

state heat conduction model, and subsequently used in the heat ux model in a iterative manner.
Maekawa et al. [9] used nite element model to evaluate eect material properties and coolant
heat transfer coecient (030,000 W/m2 K).
Komanduri and Hou [6] presented analytical solutions for determining temperature rise in the
chip and in the tool. The equation for the chip was derived based on assuming an oblique moving
band heat source for an innite medium with adiabatic boundary condition on the upper surface
of the chip. The solution for the temperature rise in the tool is obtained with the assumption of an
induced stationary rectangular heat source caused by the shear plane heat source.
Huang and Liang [5] presented a cutting force model that includes the eect of temperature
dependent thermal properties on the cutting forces through a modied constitutive relation
involving strain, strain rate and temperature. The thermal model was based on analytical solutions for temperatures derive based on the assumption of a uniform moving oblique band heat
source to approximate the eect of primary shear zone heat generation and a uniform moving
band heat source within a semi-innite media for the eect of secondary shear zone heat source.
Chou and Song [3] used similar cutting force model to evaluate the tool temperature rise. The
thermal model was based on discretizing the primary and secondary heat sources into small segments of rectangular heat source and using superimposition techniques. The temperature rise due
to the overall heat source was estimated by super imposing all temperature rise by the individual
small heat source segments. The solution for individual segments of heat source was based on the
analytical model developed by Komanduri and Hou [6].
The nite element analyses of Tay et al. [16], Muraka et al. [10] and Stevenson et al. [13] account
for the primary and secondary zones arising from the fact that plastic deformation takes place
over substantial zones both around the shear plane and rake face of the tool. Tay et al. [16] used
nite element method to compute temperature distribution in orthogonal machining with continuous chip formations. The model was based on a two-dimensional steady state heat equation with
heat source. The distribution of heat sources in both primary and secondary zones was calculated
from the experimental data on strain rate and ow stress distributions obtained by Stevenson and
Oxley [15]. Muraka et al. [10] and Stevenson et al. [13] in their study of the temperature distribution using nite element method also used similar approach.
Lazard and Corvisier [7] presented analytical prediction of temperature and heat ux at the tool
tip using a quadruple formulation that incorporates a inverse heat conduction techniques and
measured temperature inputs from two thermocouples in the insert tool.
Chan and Chandra [2] analyzed thermal aspects of orthogonal metal cutting process using twodimensional boundary element method. The thermal model was based on the assumption of a
concentrated heat generation along the shear plane for primary shear zone heat generation.
The heat generation in the secondary zone and frictional heating was assumed as 25% of the primary shear zone heat generation and concentrated along the plane.
The objective of this study is to develop a nite element based computational model to determine temperature distribution in an orthogonal metal cutting process. The model is based on
multi-dimensional steady state heat diusion equation along with heat losses by convection lm
coecients at the surfaces. Additionally, the model takes into account the geometry of the workpiece/chip/tool, convective losses, and the temperature dependent thermo-physical properties of
the materials. A parametric study will be carried out to investigate the eect of operating conditions on the thermal characteristics of the tool, chip and the workpiece.

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2. Analytical model
In this section a description of the idealized model for machining, a model for heat generation
and the heat conduction model for dissipation of heat in the workpiece, tool and the chip are presented. Fig. 1 shows a typical machining process. There exists a shear plane at an angle, / from
the direction of cut. The material undergoes plastic deformation when it approaches shear plane
and undergoes a concentrated shear process when it passes the shear plane. The region around the
shear plane is called the primary shear zone. The work needed to cause the plastic deformation is
primarily transformed into heat in this primary shear zone. It has also been established that additional plastic deformation and frictional heat generation takes place over a secondary shear zone
adjacent to the rake face of the tool. As the tool moves through the workpiece, the chip is separated from the workpiece and moves over the rake face of the tool, causing further plastic deformation and heat generation in the secondary shear zone adjacent to the toolchip interface.
In this process, the mass of material removed by shearing of the workpiece in the region of the
shear plane is plastically deformed, i.e. a large amount of energy has to be used to form the chip
and move it along the rake face of the tool. Energy is also needed to form the two new surfaces.
So, the total energy needed is a combination of the energy needed to form the chip and to form the
new surfaces. However, the minimum energy needed to form the new surfaces is signicantly
smaller than that used for deforming the material that is removed.
There are two basic approaches for studying machining processes [18]: 1. minimum energy principle and 2. slip-line eld theory. In the minimum energy principle, it is assumed that the plastic
deformation occurs only in the shear plane. So the cutting energy is calculated from the shear

Fig. 1. Typical geometry of cutting process.

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2157

strain and the shear stress at the shear plane. In the slip-line eld theory, it is assumed that the
continuous chip formation in the shear zones, i.e. continuous plastic deformation around the
shear plane. The present study is based on the slip-line eld theory.
2.1. Heat generation
As a rst approximation, it can be assumed that all of the mechanical energy associated with
cutting or chip formation is converted into thermal energy. The energy that is not converted into
thermal energy, such as the energy retained in the chips and that associated with the generation of
the new surface area is negligibly small. It has been often assumed that the chip is formed instantaneously at the shear plane, so that a uniform plane source and velocity discontinuity may be
assumed to exist there. The secondary deformation zone has usually been neglected and the
toolchip interfacial friction heat source taken as uniform. Stevenson and Oxley (14) have demonstrated through their experimental studies that plastic deformation takes place substantially
over the primary and the secondary zones. However the secondary shear zone is negligibly small
at lower cutting speeds. The heat sources are estimated based on the measured shear stress and
shear strain rate relations in the deformation zones as follows:
2.1.1. Primary zone
Assuming that the work of deformation is the energy converted into thermal energy, the rate of
heat generation per unit deformed volume is expressed as
Q_ s_c r_e

The stress and the strain rate have to be estimated from the experimental data or relations.
2.1.2. Flow stress
The stressstrain relations for typical steels are non-linear due to the higher rate of strain hardening at lower strains. The non-linear stressstrain relations for typical steel is expressed as,
r r1 en

where r and e are the uniaxial stress and strain. The uniaxial stress and the strain are assumed
to be related to shear stress, s and shear strain c through the Von Mises criterion, which is stated
as
r 30:5 s
e

c
30:5

3
4

c_
5
30:5
Stevenson and Oxley [15] presented empirical values of r1 and n based on their slow-speed compression test and experimental data given by Roth [12] for a range of slow cutting speed. In this
study, these empirical values are used along with Eqs. (1)(5) to estimate the shear stress in the
primary zone.
e_

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2.1.3. Strain rate

In order to study the plastic deformation in the shear zones, Stevenson and Oxley [14] used an
explosive quick stop device together with a printed grid (0.00508 mm2). Experiments were conducted under orthogonal cutting conditions and deformed grids were obtained over a range of
operating conditions: rake angle(1030), cutting speeds(5.18249 m/min) and depths of
cut(0.1270.274 mm). The cutting force components FP were measured using a dynamometer
that consisted of an arrangement of semiconductor strain gauges bonded with the tool-holder.
Based on this deformed grid, they have estimated the strain rate in the vicinity and the shear
plane, which represents the direction of maximum shear rate. They had concluded that the maximum shear strain as directly proportional to shearing velocity VS and inversely proportional to
the depth of cut t1 and presented following empirical equation for maximum shear strain as
c_

2:59V S
t1

The shearing velocity is given by

VS

0:2U cos a
cos/
a

In this study, Eqs. (6) and (7) are used to estimate the heat generation rate in the primary shear
region. In order to estimate the heat generation rate per unit volume, it is essential to know the
size of the primary shear zone. Stevenson and Oxley [14] also presented the size of the shear zones,
which was obtained based on the deformed grid. In this study, this size is reproduced and used in
the computations.
2.1.4. Secondary zone
The plastic deformation in the secondary zone is strongly inuenced by the cutting speed. At
low cutting speeds, there is only frictional drag of the chip along the rake face. Under such cases,
the secondary zone can be considered as a plane frictional heat source with minor error. This frictional heat generation rate per unit area at a point on the contact length is estimated as
qS s x V x

At higher cutting speeds, the secondary zone heat source is more spread out. Observation of deformed grids indicated that a triangular region might approximate the secondary zone. For normal cutting condition there is a plastic state of stress in the chip adjacent to the toolchip interface
along most of the contact length. Only towards the end of the contact, where the chip starts to curl
away from the tool, the stress becomes elastic. Assuming that the elastic part of the contact is negligible and assuming that the interface is in the direction of maximum shear stress, the shear ow
stress is estimated as,
ssec

Ff
Hw1

Also, assuming that the interface is in the direction of maximum shear strain rate and the velocity
changes from zero at the tool face to bulk chip velocity Vc across the plastic zone thickness tp, the
maximum strain rate is estimated as

P. Majumdar et al. / Applied Thermal Engineering 25 (2005) 21522168

c_ sec

V
tp

2159

10

The maximum thickness of the plastic zone is expressed as

tp dt2

11

Stevenson and Oxley (10) has measured the distortion along the toolchip interface based on the
deformed grids and estimated an approximate value of d = 1/8, for the cutting conditions
considered.
The heat generation rate per unit volume at any point in the secondary zone is expressed as
qS ssec c_ sec

12

Eqs. (8)(12) are used to establish heat generation in the secondary zone.
2.2. Heat conduction model
The heat generated in the shear zones and at the rake face is dissipated in the chips and workpiece by conduction and lost to the ambient by convection. These heat transfer phenomena that
occur during metal cutting processes are governed by heat conduction equation. Following
assumptions are made in developing the heat conduction model: 1. the process is steady, 2. the
problem is two-dimensional, 3. the heat generation is uniformly distributed over the primary
and the secondary zones, and 4. Convection losses can be approximated by constant convection
transfer coecients.
The mathematical statement of the heat conduction process is given as
 2



o T o2 T
oT
oT
v

Qx; y qC P u
0
13
k
ox2 oy 2
ox
oy
which is subject to the following boundary conditions:
T T1

14

oT
hc T
T 1
15
on
The convection lm coecients for the dierent surfaces have been arrived at by using the standard correlations for free convection and boiling for horizontal, vertical and inclined surfaces.
Fig. 2 shows the heat generation and dierent convective conditions used on dierent surfaces
of the model.

k

3. The nite element formulation

The complexity of the solution domain and boundary, and heat source distribution within primary and secondary zones, dissimilar materials for workpiece/chip and tool-tip and temperature
dependent thermo-physical properties precluded use of any analytical solution or nite dierence
code. The nite element method is particularly suitable for such complex domains and boundaries

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Fig. 2. Heat source and boundary conditions for the model.

and therefore selected for this study. Additionally, the element forming the mesh can easily be varied in size; number and orientation to model localized concentration of heat sources and temperature gradients. In this study the nite element code ANSYS is used for solving the governing Eqs.
(13) through (15). The element used for the computation is a plane element with a two-dimensional thermal conduction capability. This is a four node quadrilateral element with a single degree of freedom, temperature at each node.
3.1. Mesh generation
This is the most important step in the nite element procedure as this determines the accuracy
of the results. Since the model generated was an irregular geometry, mapped meshing could not be
used and so free meshing was used. Automatic generation of the elements was not adopted since
this would result in uniform meshing and the result will not be that accurate. So the elements were
created for dierent parts of the model individually so that a very ne mesh distribution could be
used in the critical areas and more course mesh distribution could be used in less critical areas
such as the far ends of the work piece, tool and the chip. A ner mesh was used in the critical
areas such as the primary zone, the toolchip interface and parts of the chip, work piece and
tool-tip closer to the primary zone and the interface.

4. Results and discussion

In this section, the heat conduction model will be used to predict the temperature distribution in
the tool, chip and work piece. The workpiece material that was considered was free machining
steel and the cutting tool-tip material was tungsten carbide. The temperature dependent
thermo-physical properties of the tool and the work piece are curve-tted and used in the compu-

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Table 1
Cutting conditions
Cutting condition

Work speed (m/min)

Cutting force (N)
Feed force (N)
Chip speed (m/min)
Shear angle (deg)
Contact length (mm)
Maximum width of secondary zone

29.6
3240
550
13.8
30
0.68
Negligible

78
3360
666
35.4
28.5
0.82
0.09

155.4
3750
1190
68.9
27.8
0.91
0.1

Table 2
Material properties
Workpiece/chip
Material
Free machining steel
Density (kg/m3)
7871
Thermal conductivity, K(T) 79.39
5.60 10
2T + 2.09 10
5T2

2.57 10
8T3 + 1.302 10
11T4
Thermal conductivity
60.318 W/m K (at 473 K)
Specic heat capacity, C(T) 875.49
3.04T + 7.5 10
3T2

6.74 10
6T3 + 2.2 10
9T4

Tool
Tungsten carbide
8190

28.91 + 0.247T
3.7 10
4T2 + 1.92 10
7T3
24.1 W/m2 K (at 473 K)
1371.9
0.125T2
9.91 10
6T3 + 2.65 10
9T4

tations. The properties of these materials are given in Table 2. The analysis is carried out for three
dierent cutting conditions as given in Table 1. A pre-conditioned iterative conjugate gradient solver is used to solve the system of equations. The iterations are continued until convergence is
reached within a tolerance limit, es = 10
6.
4.1. Mesh renement study
Since nite element analysis is a numerical method, the mesh size is an important factor aecting the precision of the results. In this study, eight dierent mesh size distributions in the primary
shear zone and ve dierent mesh size distributions in the tool are used. Since the critical area of
the model is the primary zone and the toolchip interface, the mesh sizes were rened only for
these two areas. Numerical values for temperatures at selected points on the shear plane are presented in Table 3 and Fig. 3. Results show that in the beginning, for cases 15, temperature distribution oscillates as number of elements is increased and with further renement of meshes as in
case 68, the distribution converges. The percent relative errors are also estimated and presented
in Fig. 4. The results show that the percent relative error decreases with oscillation. Results show
the downward trends with oscillation. Temperatures at selected points converge to values with
percent relative error less than 2% for the case 7 with number of elements in the primary zone
as nep = 1633 and the number of elements in the tool as, net = 884. The rest of the analysis is carried out based on these mesh size distributions.

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Table 3
Temperature at selected points on shear plane for dierent meshes
Number of Elements
Tool

122

178

283

542

663

795

884

987

Primary Zone

205

332

544

1338

1441

1454

1633

2045

S.No.

X, mm

Y, mm

Case-1

Case-2

Case-3

Case-4

Case-5

Case-6

Case-7

Case-8

1
2
3
4
5

5.142
5.191
5.241
5.304
5.504

1.664
1.621
1.577
1.533
1.4

601.17
568.48
598.88
601.71
591.66

544.97
529.34
556.94
551.29
556.62

561.3
531.22
569.13
560.57
567.23

543.34
523.36
550.11
547.87
543.29

583.11
561.38
593.65
586.41
592.61

616.45
604.26
626.89
621.29
631.14

628.61
612.22
638.32
633.69
636.46

638.13
621.35
646.14
646.69
644.42

Fig. 3. Temperature at selected points on the shear plane for dierent meshes.

Fig. 4. Percent dierent error for dierent meshes.

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2163

4.2. Temperature distributions

The results obtained for the condition-1 with cutting speed of 29.6 m/min are presented for the
entire region as temperature contours in Fig. 5. It can be seen clearly that high temperature region
occurs in the chip and tool region with maximum temperature appears at the interface of the chip
and the tool at a distance, h = 0.4896 mm from the tip along the interface. This is due to the fact
that most of the energy of deformation is transformed into heat in the chips. This heat energy is
subsequently dissipated in the chips, as well as in the workpiece and the tool by conduction. Since
the contact surface acted as plane source, the maximum temperature appears along this contact
line. In order to get a closer picture of the heating eect; the temperature distributions are analyzed
for ve selected lines as shown in Fig. 6. Lines A, B and C are selected to cover the primary zone.
The line D is along the toolchip interface. The line E is selected inside the tool at a depth of 0.1 mm
from the toolchip interface. The results are presented in Fig. 7. It clearly shows a higher temperature gradient towards the chip from the primary shear plane line A. For example, the temperature
level in the line C located in the chip is higher than that in line B located in the work piece, and even
higher temperature level along line D at the interface. The maximum temperature is found to be
T = 709 K at a distance of h = 0.4896 mm near the point 5 on this line. The temperature level is
reduced in the interior region of the tool, but still signicantly elevated compared to the work piece.
4.3. Eect of cutting speed
The major operating parameters that have signicant eect on the heat generation and distribution temperatures are, cutting speed, feed rate and depth of cut. In this study, attention is

Fig. 5. Temperature distribution for cutting condition-1.

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P. Majumdar et al. / Applied Thermal Engineering 25 (2005) 21522168

Fig. 6. Selected lines and points for temperature distribution.

Fig. 7. Temperature distribution along selected lines for cutting condition-1.

P. Majumdar et al. / Applied Thermal Engineering 25 (2005) 21522168

2165

Fig. 8. Temperature distribution for cutting condition-2.

Fig. 9. Temperature distribution for cutting condition-3.

primarily focused on the eect of cutting speed. Investigation is carried out for cutting speeds of
29.6 m/min, 78 m/min and 155.4 m/min. The results are presented for entire region as contour

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Fig. 10. Variation of shear plane temperature with cutting speed.

Fig. 11. Variation of toolchip interface temperature with cutting speed.

plots in Figs. 5, 8 and 9. As expected the temperature levels is higher for the cutting conditions 2
and 3 because of higher heat generation in the primary as well as in the secondary zone with higher cutting speeds. For purpose of closer look, the temperature distributions in the shear plane and
in the toolchip interface are presented in Figs. 10 and 11 respectively. It can be seen from Fig. 10
that the temperature in the shear plane increases with cutting speed and the maximum temperature along the shear plane occurs somewhere in the middle as expected because of convection heat
losses. This behavior is similar for all three cutting conditions and is more pronounced for higher
cutting speeds. Fig. 11 shows that the maximum temperature occurs along the toolchip interface
at a distance from the tool-tip for all three conditions. The maximum temperature increases with
higher cutting speeds, and the location of the maximum temperature moves away from the tooltip for higher cutting speeds due to higher convection heat losses near the tip. This eect was more
apparent in the cutting condition 3. The maximum temperature in the tool increased from
709.36 K to 1320 K as cutting speed is increased from 29.6 m/min to 155.4 m/min.

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2167

Fig. 12. Variation of maximum temperature with heat transfer coecient.

4.4. Eect of heat transfer coecient on maximum temperature

In order to see the eect of coolants and boiling heat transfer coecient, computations are carried out over a typical range of boiling heat transfer coecient [4] in regions where cooling is produced by liquids. Results presented in Fig. 12 shows that the maximum temperature in the tool
decreases with increase in the boiling heat transfer coecient. The maximum temperature decreases by 9.3% as the boiling heat transfer coecient is increased from 13,000 W/m2 K to
25,000 W/m2 K.

5. Conclusion
A nite element based computational model is developed to study the temperature distribution
in the tool and work piece/chip during metal cutting process. The model displayed increased temperature distribution in the tool, with the maximum temperature occurring at the toolchip interface. A parametric study is carried out to predict quantitatively the increased temperature level in
the tool with increased cutting speed. The maximum temperature in the tool increased from
709.36 K to 1320 K as cutting speed is increased from 29.6 m/min to 155.4 m/min. The model also
showed signicant eect of conduction and convection losses in heat dissipation and temperature
rise in the tool. The maximum temperature decreased by 9.3% for the case with cutting speed of
29.6 m/min as the convection heat transfer coecient is increased from 13,000 to 25,000 W/m2 K.

References
[1] M.B. Bever, E.R. Marshall, L.B. Ticknor, The energy stored in metal chips during orthogonal cutting, Journal of
Applied Physics 24 (1953) 11771179.
[2] C.L. Chan, A. Chandra, A boundary element method analysis of the thermal aspects of metal cutting processes,
Transactions of the ASME Journal of Engineering for Industry 113 (1991) 311319.
[3] Y.K. Chou, H. Song, Thermal modeling for nish hard turning using new tool, in: Proceedings of the 2003
International Mechanical Engineering Congress, 2003, pp. 183191.

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