FEM- based thermal modelling of the cutting process using power law-temperature dependent concept

Purpose: Purpose of this study is to compare two variants of the FEM simulation model of orthogonal cutting process of AISI 1045 carbon steel with uncoated and multilayer-coated carbide tools i.e. standard and Power Law–Temperature Dependent (PL-TD) options. The primary reason for undertaking this problem was unsatisfactory accuracy of the predictions of cutting temperature especially for coated cutting tools. Design/methodology/approach: Methodology used employs the Lagrangian-FEM model with more accurate thermophysical properties of the substrate and coating materials. All thermal properties (thermal conductivity and diffusivity and specific heat) are expressed in the forms of polynomial models of the 5th degree. Multi-layer coating is substituted by homogeneous monolithic layer with equivalent thermal properties. In addition, these simulation algorithms use the Johnson-Cook constitutive law. Findings: Basically, the FEM package applied allows the temperature distribution and heat flux intensity to be predicted closer to appropriate measurements and computations. Research limitations/implications: Research limitations deal with the lack of reliable data and models for both cutting tool and workpiece material. Future research should be focused on other coatings which are commonly used in cutting tool industry. Practical implications: They can be related to more detailed inputs from research and developing centers which exist in many leading branches of industry. Unfortunately, academic approach is sometimes very narrow and does not consider real machining conditions. Originality/value: Originality of this simulation approach can be seen in elaborating more accurate models for thermal properties. Moreover, it contributes to finding some fundamental relationships between all physical phenomena involved into tool-chip contact behaviour.