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CIRP Annals - Manufacturing Technology

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Temperature calculation in cutting zones

Hans-Christian Möhring (2)a,*, Valerii Kushner b, Michael Storchak a, Thomas Stehle a
a
Institute for Machine Tools, University of Stuttgart, Germany
b
Department of Mechanical Engineering and Material Science, Omsk State Technical University, Russia

A R T I C L E I N F O A B S T R A C T

Keywords: This paper presents methods for refining the calculation of cutting temperatures. The heat flow densities
Cutting
and temperatures in the chip forming area, the accumulation zone and the area of the plastic contact
Temperature
between chip and tool affect the cutting temperature considerably. The new method takes the heat
Modelling
distribution for moving sources into account. The temperature in the contact between the flank face and
the workpiece is calculated considering how friction and the accumulation zone affect the cutting
temperature in the tertiary cutting zone. The methods incorporate material softening during temperature
increase. The models are verified by experimental analyses.
© 2018 Published by Elsevier Ltd on behalf of CIRP.

1. Introduction
Modelling of cutting processes can be used to determine
resultant forces as well as the temperature distribution and heat
flow density in the cutting zones [1]. Analytical cutting models so
far mostly neglect a correlation between the temperature and the
resistance characteristics of the material to be machined. This
correlation is, however, significant for describing the effect of the
cutting conditions on the temperature accurately. In the past,
numerous analytical models for the calculation of cutting
temperatures were developed and experimental analyses of the
temperature distribution in tools, workpieces and in the contact
between these objects were conducted [2]. In Ref. [3], the cutting
process was regarded in the chip forming plane. A plane heat
distribution in the heat exchange was assumed. The process of
three-dimensional cutting was derived from a plane process with
varying depth of cut along the cutting edge of the tool. To establish
the temperature on the rake face, heat sources were considered
with respect to the deformation of the material in the chip forming
area as well as to the deformation and friction in the contact of the
chip and the rake face. The temperature distribution along this
contact was calculated from the joint effect of the heat sources.
Based on the analytical solution by Hahn [4], modified by Chao and
Trigger [3], Komanduri and Hou examined a temperature
distribution due to deformation in the shear plane in orthogonal
cutting [5]. They also modelled a temperature distribution
applying the method of moving source by Carlsaw and Jaeger
[6]. Recently, additional methods for the analytical modelling of
the temperature distribution in the cutting zones were used [7–9].
In summary, until now, analytical models of the temperature
distribution are calculated in two heat emission zones (chip
* Corresponding author.
E-mail address: hans-christian.moehring@ifw.uni-stuttgart.de (H.-C. Möhring).
forming area and rake face). In each zone, two bodies are in contact
(chip and workpiece in the shear plane; chip and tool at the rake
face). In these zones, the heat flow density was analysed. A
distribution of the general output of the heat sources between the
bodies in contact was taken into account by two principle
approaches. On the one hand, a distribution of the heat flow
density is established from the heat source that is independent of
temperature. These temperature distributions are used as bound-
ary conditions [3]. On the other hand, the temperature is calculated
considering the correlation between temperature and heat flow
density. This is done by the joint solution of the thermal
conductivity equation and the constitutive equation.
This paper introduces an analytical cutting temperature
calculation by taking the dependence of the heat flow density
on the temperature into account as well as the peculiarities of the
heat distribution at exemplary cutting speeds for AISI 1045 steel. In
addition to the shear plane and the rake face, the accumulation
zone and areas of plastic contact are considered.
2. Model approach
The analytical calculation model of the temperature distribu-
tion regards orthogonal cutting (Fig. 1).
The following heat sources are considered: material deforma-
tion in chip forming area A; material deformation under adiabatic
conditions in accumulation zone B on the rake face; plastic contact
between the chip and the rake face in the zone C; plastic contact
between tool and workpiece due to the material deformation
under adiabatic conditions and an intensive heat dissipation
perpendicular to the cutting speed in the accumulation zone G. The
temperatures are established separately for each cutting zone. The
directions and the quantity of the heat flows which are diverted
from the heat sources into the chips, the workpiece and the tool are
characterized by certain peculiarities which simplify the tempera-
ture calculation.

https://doi.org/10.1016/j.cirp.2018.03.009
0007-8506/© 2018 Published by Elsevier Ltd on behalf of CIRP.

Please cite this article in press as: Möhring H-C, et al. Temperature calculation in cutting zones. CIRP Annals - Manufacturing Technology
(2018), https://doi.org/10.1016/j.cirp.2018.03.009
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and heat flows with subsequent iterations. Small areas of the

Fig. 1. Layout of heat flows in orthogonal cutting.
The Péclet similarity criterion [5],
vh
Pe ¼ ; ð1Þ
v
with cutting speed v, undeformed chip thickness h and
coefficient of thermal diffusivity v, constitutes a ratio between
convective and molecular heat transfer. It is increased with rising
cutting speed and undeformed chip thickness. When Pe is
increased, the movement of the workpiece material provides an
increasing major part of convective heat transfer compared to a
decreasing minor conductive heat flow from the chip forming area
into the workpiece. Correspondingly, with increasing cutting
speed, more heat is transferred by convection than by conductivity
into the tool which is fixed relative to the heat sources. The heat
flows normal to the velocities of the workpiece or the chip do not
prevent a convective heat exchange. Though, heat flows in the
directions of these velocities arise due to thermal conductivity.
Consequently, quasi-stationary two-dimensional temperature
fields in the chip and the workpiece can be expressed as one-
dimensional temperature fields.
The temperature calculation applies the method of moving
sources [10]. The temperatures in a half plane for the layout in Fig. 1
are established with the following equation:
rffiffiffiffiffiffiffiffiffiffiffiffi
2 q x
uð0; xÞ ¼ pffiffiffiffi  f  ; ð2Þ
p CV v1  v
accumulation zone close to the cutting edge, in which the yield
point of the machined material and thus the heat density increase
up to the maximum, are taken into account.
It is required to obtain the distribution of the heat flows in the
areas of the plastic contact between chip and tool as well as in the
accumulation zone in the contact between tool and workpiece by
jointly solving the equation of thermal conductivity and the
constitutive equation. The thermomechanical model of the
material resistance to cutting [12] is used here as constitutive
equation, which connects the yield point to the temperature
during material deformation under cutting conditions. The heat
flow density in the chip forming area and in the area of the plastic
contact between chip and tool is calculated on the basis of this
material model. The heat flow density in the areas of the elastic
contact between chip and tool (E) as well as the elastoplastic
contact between tool and workpiece within the wear land are
assumed to be independent of temperature. These heat flow
densities are established by superposing the solutions for evenly
distributed heat sources and heat flows.
3. Temperature distribution in the chip
The temperature of the chip close to its contact with the tool
depends on two heat sources (Fig. 1): a heat source in the chip
forming area A due to material deformation and a heat source in
the contact between the chip and the rake face of the tool as a
result of the material’s plastic deformation. These contacts are the
accumulation zone B, the zone of the plastic contact C and the zone
of the elastic contact E. Passing through the chip forming area, the
material to be machined is evenly warmed up to the deformation
temperature. This temperature depends on the specific deforma-
tion work, the heat flow from the chip forming area into the
workpiece and the specific heat capacity of the material. The
material hardens in the area B with the length CH. Its yield point
~ here. The material softens in the area
attains the maximum value q
C of the plastic contact C1 with the length CS. This occurs due to the
influence of the temperature on the hardening effect of the strain
rate [12]. In accordance with a linear law, the heat flow density
decreases in the area E of the elastic contact between chip and tool
with the length CE. Friction is considered here by means of a
constant tangential stress.

with real coordinates x, the density of the evenly distributed 3.1. Calculation of the deformation temperature
heat flow qf, the specific volumetric heat capacity of the material to
be machined Cv, and the speed of the chip v1. Considering In order to take account of how the heat flow density in the chip
forming area and the heat flow from the chip forming area into the
v workpiece affect the deformation temperature, an elementary
qf ¼ qF  v1 and v1 ¼ ; segment of the shear plane is assumed as a point heat source with
Ka
the heat flow density qw. This point heat source moves at the speed
vn normal to the shear plane (Fig. 2).
0 2 q pffiffiffiffiffi
DT  pffiffiffiffi  F  A1  Pe
p Rt
with the chip compression ratio Ka and the mean specific
tangential force in the area of the plastic contact between chip and
tool qF [11], it is possible to calculate the increase in homologous
temperature according to the following equations:
sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
0 Duð0; xÞ 2 qF Rt vh x 1
DT ¼ ¼ pffiffiffiffi      ð3Þ
Gm p Rt CV  Gm v a Ka

Rt 0 2 q pffiffiffiffiffi
A1 ¼ and DT  pffiffiffiffi  F  A1  P e
C V  Gm p Rt
with the melting temperature Tm, and the effective ultimate
strength Rt. The temperature calculation is established by
superposing the solutions for evenly distributed heat sources Fig. 2. Layout for calculating the deformation temperature.

Please cite this article in press as: Möhring H-C, et al. Temperature calculation in cutting zones. CIRP Annals - Manufacturing Technology
(2018), https://doi.org/10.1016/j.cirp.2018.03.009
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The heat flow density qW is in proportion to the specific 3.3. Calculation of the temperature distribution in the area of the
deformation work Aw [11], which is obtained by analytical plastic contact between chip and tool
approaches of the material model [12]. Based on Eq. (2), the
temperature distribution normal to the shear plane (see x-axis in The greatest yield point of the machined material is constant and
Fig. 2) is established by Eq. (4). The deformation temperature ud0 of considerably greater than the mean tangential forces on the rake face
the machined material, which is diverted from the chip forming of the tool [11]. Hence, the yield point and the heat flow density
area into the chip, is calculated under presumption that the whole decrease in the area of the plastic contact between chip and tool with
heat, which is equivalent to the deformation work, is evenly growing temperature. The heat flow density (yield point) and the
distributed within the chip. mutual temperature distributions in the area of the plastic contact
between chip and tool are calculated here by numerical methods. For
8
>   vn  x  v  x
n
>
> q   this, the area of the plastic contact is divided into a certain number of
>
>
w
e v ¼ u d0  e v ; by x > 0
>
> vn  C V intervals. In each interval, the temperature distribution in the length
>
>
< of the plastic contact is approximated by superposing the solutions
uðxÞ ¼    
> qw Aw for the temperature of evenly distributed heat sources with the
>
>
> ¼ ¼ ud0 ;
>
> vn  C V CV density q0 and of evenly distributed heat dissipations. A decrease in
>
>
>
: by x < 0 heat flow density is taken into account here for every interval due to
the growing temperature.
ð4Þ Fig. 3 shows the scheme for establishing the temperature and
the heat flow density in the first distribution interval. The
Hence, the following system equation can be used to describe distribution of heat flow density and temperature is represented
the dependence of the deformation temperature on the true final as a joint effect of the evenly distributed heat sources with the
shear under adiabatic conditions and with respect to the density of the heat flow (Eq. (7)) and the evenly distributed heat
regularities of the material’s hardening and softening in the chip dissipations. These heat dissipations are introduced individually
forming area [11]: into each interval. They take account of the decrease in heat flow
8   density due to the temperature increase.
> 1 A  A1  B  K 1þm
>
>
>  ln 1 þ  ew by ew < ~et
>
> B  A1  C V  1þm 
< 1 A  A1  B  K 1þm
ud0 ðew Þ ¼  ln 1 þ  ew 
>
> B  A1  C V  1þm
>
>
>
> B1 t~ t p ðew Þ
:    Þ  ðew  ~et Þ by ew > ~et ;
CV Rt Rt
ð5Þ

  1
m  ð1 þ mÞ 1þm t ~ em
~
et ¼
where ~ ; ¼ AK t ; ð6Þ
A  K  A1  B Rt 1þm

Rt npffiffiffihpffiffiffi im o1
A1 ¼ ; A ¼ 3 3lnð1 þ ew Þ ;
CV  T m

where m is the exponent of the deformation hardening in

standardized tensile and compression tests and ew is true final
shear. The empirical coefficients K, B and B1 are gathered by
comparing the specific tangential forces obtained by experiment Fig. 3. Scheme for calculating the temperature on the tool rake face.
with the analytically calculated values [11,12].

3.2. Estimation of the maximum heat flow density on the boundary The decrease in the heat flow density qip at the i-th interval and
between the accumulation zone and the area of plastic contact the p-th iteration due to the growing homologous temperature Tip
is approximated with an empirical power function where Td is the
Greater specific tangential forces are attained in the accumula- deformation temperature in the cutting zone A:
tion zone B (Fig. 1) than in the chip forming area [11]. This is due to !Bq
the great effect of the strain rate, as the deformations are T 10
distributed more evenly in the accumulation zone and the q11 ¼ q0  1 ð8Þ
1  TTmd
homologous temperature is higher. The maximum dimensionless
heat flow density and the corresponding yield point represent the The decreasing heat flow density in the first interval from q0 to
only temperature-independent information about the heat flow q11 in the first iteration p = 1 is taken into account by introducing
density in the area of the plastic contact between chip and tool. the heat dissipation:
This information can be used for calculating the temperature
q0  q11
distribution on the rake face of the tool in the area of the plastic K 11 ¼ ð9Þ
2
contact between chip and tool.
As the deformation conditions in the accumulation zone B are Including the heat dissipation K11, the temperature at the end of
nearly adiabatic, the maximum values of the dimensionless heat the first interval is:
flow density (shear yield point) q ~ can be calculated with equations pffiffiffiffi
analogously to (6): T 11 ¼ T 10  A0  K 11  H ð10Þ

For the transition to the second interval (i = 2), the temperature

  1 T1r, which is calculated at the last iteration of the first interval, is
A  K q  ~eq
m
~
q m  ð1 þ mÞ 1 þ m ð7Þ
where eq ¼
~m
¼ extrapolated on the length 2H and the cycle is repeated.
Rt 1þm A  K q  A1  B
Comparing the calculated temperature distributions and the
The empirical coefficient Kq is established from the resultant dimensionless heat flow densities, or rather the dimensionless
forces obtained by experiment. specific tangential forces obtained for different values of the Pe

Please cite this article in press as: Möhring H-C, et al. Temperature calculation in cutting zones. CIRP Annals - Manufacturing Technology
(2018), https://doi.org/10.1016/j.cirp.2018.03.009
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criterion, shows that a growing Pe criterion leads to an increase in
temperature on the rake face of the tool and a corresponding
decrease in heat flow density (specific tangential forces). This is
confirmed by experimental data [11,12].
4. Temperature in the accumulation zone on the flank face
A zone of plastic deformations G arises in the contact between
the flank face of the tool and the workpiece (Fig. 1). The
distribution of the heat flow density (specific tangential forces)
on the supporting chamfer at the tool is assumed to be constant:
qf
 0:35 ð11Þ
Rt
A great decrease in heat flow density is taken into consideration in
the transition to the hardening chamfer by means of extending the
heat source acting in the accumulation zone and the heat
dissipations to the area of the elastoplastic contact. Moreover, a
heat dissipation is added considering a decreasing heat flow density.
Consequently, the temperature on the flank face near the cutting
zone decreases with growing distance from the cutting edge. This
temperature reaches a minimum and then increases further.
5. Verification of the developed model
The calculated cutting temperature, using the model developed,
was compared with measured data. The temperature was
measured during the orthogonal cutting process on the exterior
surface of the chips. The measurements utilized a high-speed
pyrometer. The measuring field of the pyrometer was directed
towards the exterior surface of the chip root. In order to guarantee
varying final shears, the tool rake angle and the cutting speed were
changed so that the Pe criterion was 10, 20, 40 and 80 for a constant
undeformed chip thickness of 0.3 mm. Fig. 4 shows the tempera-
ture on the exterior surface of the chip, depending on final shear.
Fig. 4. Comparison between calculated and measured temperature on the exterior
surface of the chip.
The test set-up from Ref. [13] is used for measuring the cutting
temperature on the flank face of the tool in turning processes. Fig. 5
presents the comparison between the calculated and the measured
temperature on the wear land of the flank face.
Fig. 5. Comparison between calculated and measured temperature distributions on
the wear land of the flank face.
Experimental data from Ref. [14] is used for comparing the
calculated temperature distribution on the rake face of the tool
(Fig. 6). The greatest difference between calculated and experi-
Please cite this article in press as: Möhring H-C, et al. Temperature calculation in cutting zones. CIRP Annals - Manufacturing Technology
(2018), https://doi.org/10.1016/j.cirp.2018.03.009
Fig. 6. Comparison between calculated and measured temperature distribution on
the rake face.
mental values is 17%. Thus, the calculated data shows a good
agreement with the experimental ones.
6. Summary and outlook
When determining the deformation temperature, it is taken
into account how the temperature affects the specific deformation
work as well as the specific tangential forces. In addition, the
softening of the material is examined here owing to the
localization of the deformation in a narrow region of the chip
forming area. In the case of conventional cutting parameters
(Pe = 20 . . . 150), the heat flow from the chip forming area into the
workpiece reduces the deformation temperature only insignif-
icantly. With increasing Pe criterion, there is a greater effect of this
heat flow on the temperature. The numerical iteration method
proposed here can be used to calculate alternating distributions of
the temperature and the yield point in the area of the plastic
contact between chip and tool as well as in the accumulation zone
on the flank face. A comparison between the measured and the
calculated temperature on the rake and flank faces of the tool
confirms the quality of the developed method.
In future work, the modeling approach will be enhanced in part
by considering the effect of the tool flank wear on the cutting
temperature and transferred to more complex cutting conditions.
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