Velocity plane-based analytical modeling for reconstructing temperature field at tool-chip/work interface

Analytical thermal modeling is expected to be an efficient method for a rational heat dissipation strategy and quality assurance of products in oblique cutting processes. In contrast, conventional metal-cutting models are mainly limited to applications for lack of comprehensive analysis and unsustainable experimental validation. In this study, an improved analytical approach based on the velocity plane, including the cutting velocities, is proposed to determine the spatial distribution of heat source associated with the cutting edge inclination for addressing the geometrical complexity in the oblique cutting process. The model comprehensively considers the negative rake angle and the cutting edge inclination, nonuniform contact stress distribution at the tool–chip interface, and nonuniform partition of heat between the cutting tool and workpiece to predict the temperature distribution at the tool-chip/work interface in the oblique cutting process. To evaluate the model, a novel temperature measurement method, which can monitor the on-site temperature rise at the tool-chip/workpiece interface, was integrated at the multiple positions near the cutting edge. Experimental values measured by the sensor-integrated tool showed good consistency with the predicted value calculated using the analytical thermal model. Our proposed model is demonstrated to successfully predict the temperature distribution on the tool, which lays a foundation for optimizing the cutting parameters and guiding the tool design during the oblique cutting process.