Thermal-mechanical model for machining with chamfered insert considering tool flank wear

The deformation of material leads to severe thermal-mechanical effects during metal cutting with chamfered insert. The high cutting temperature on the contact face results in the wear of the insert which is a critical issue. However, there is still a lack of a comprehensive understanding of thermal-mechanical effects, especially with respect to the presence of the tool flank wear. To address this, an analytical thermal-mechanical model is developed in this paper for the prediction of the temperature distribution with a worn insert based on a modified slip-line field approach. Firstly, an analytical slip-line field model is introduced based on material plasticity and ploughing theory considering the tool flank wear. The structure of the slip-line field model, especially at the dead metal zone and the flank zone, is modified to reveal the material flow mechanism. Then, heat sources, including primary heat source, secondary heat source, tertiary heat source and fourth heat source, are clarified to explain the heat generation phenomenon in the cutting process. In addition, a cutting temperature field model is developed to show the effect of tertiary heat source based on the imaginary heat source theory. Finally, the slip-line field geometry and temperature distribution are extracted from two-dimensional finite element simulation to verify the proposed model. And orthogonal experiments are carried out for measuring the maximum cutting temperature. The good agreement of predicted results, simulated results, and experimental results verifies the accuracy of the proposed model.