Transient multi-domain thermal modeling of interrupted cutting with coated tools

Karaguzel U.

International Journal of Advanced Manufacturing Technology, vol.116, no.1-2, pp.345-361, 2021 (SCI-Expanded) identifier identifier

  • Publication Type: Article / Article
  • Volume: 116 Issue: 1-2
  • Publication Date: 2021
  • Doi Number: 10.1007/s00170-021-07388-6
  • Journal Name: International Journal of Advanced Manufacturing Technology
  • Journal Indexes: Science Citation Index Expanded (SCI-EXPANDED), Scopus, Academic Search Premier, IBZ Online, Compendex, INSPEC, DIALNET
  • Page Numbers: pp.345-361
  • Keywords: Temperature modeling, Interrupted cutting, Coated tool, Tool temperature
  • Yıldız Technical University Affiliated: No


© 2021, The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature.Interrupted cutting operations, such as milling, produce fluctuating tool temperatures which directly affect the process outputs. Thus, prediction of cutting tool temperatures enables process planning, selection of materials for tool substrate and coating layers, and tool geometric design for improved productivity in machining operations. Theoretical analysis of temperature is a cost effective way to predict the tool temperatures. Considering the industrial needs, a theoretical model should be fast, easy to implement, and reliable. To that end, a novel hybrid model, which assembles analytical and numerical methods, is proposed in this study. This novel transient thermal model simulates the interrupted cutting with coated cutting tools. The proposed model includes an analytical heat flux calculation at the tool-chip interface considering the sticking-sliding contact behavior. The determined heat flux is, then, used to perform a numerical solution of the transient heat conduction problem in the cutting tool geometry with temperature-dependent thermal properties. The developed model is validated with experimental results found in literature under different cutting conditions. The results show that the model can predict the maximum temperatures generated in a thermal cycle with an accuracy of 2–10%. Thus, the proposed model can be further used to determine the process parameters, properties of coating layers, and tool geometric design.