3D Numerical Simulation and Optimization of Heat Transfer in High-Speed Drilling of XC48 Steel

3D Numerical Simulation and Optimization of Heat Transfer in High-Speed Drilling of XC48 Steel | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article 3D Numerical Simulation and Optimization of Heat Transfer in High-Speed Drilling of XC48 Steel Nesrine MELZI, Adel Haddad, Mustapha TEMMAR, Abdessabour BENAMOR, and 1 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7085345/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 22 Sep, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract In this study, a numerical approach based on thermal analysis of the cutting tool/workpiece contact is developed. The objective is to understand the thermomechanical phenomena caused by the high temperature within the cutting tool/workpiece contact during high-speed drilling. A novel methodology is proposed to determine the temperature distribution in the different cutting areas, considering heat distribution as a function of time, which is challenging to measure experimentally. The simulation results are expected to help in predicting machining uncertainties, particularly for steel, one of the widely used materials in industry. A mathematical study is conducted to model the temperature using the design of experiments (DoE) method. The second part of this work aims to optimize the cutting parameters and to analyze the influence of these conditions on the machining process. The objective is to identify which temperature values contribute to minimizing tool wear, thereby extending the tool's service life. This model enables reliable prediction of the average interface temperature between the chip, workpiece, and tool during the drilling of the XC48 steel. High-speed machining drilling simulation Cutting tools Temperature distribution Optimization Heat transfer Experimental design method Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Full Text Additional Declarations Tables 1 to 4 are available in the Supplementary Files section. Supplementary Files Tables.docx Cite Share Download PDF Status: Published Journal Publication published 22 Sep, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Accept as is for Publication 09 Sep, 2025 Reviewers agreed at journal 09 Aug, 2025 Reviewers invited by journal 17 Jul, 2025 Editor assigned by journal 16 Jul, 2025 First submitted to journal 15 Jul, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7085345","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":486906325,"identity":"f837ee16-8c8c-416b-9391-7b5ec5ce9096","order_by":0,"name":"Nesrine MELZI","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Nesrine","middleName":"","lastName":"MELZI","suffix":""},{"id":486906326,"identity":"79e03ae5-2e27-4158-a097-ffa84c56a66c","order_by":1,"name":"Adel 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06:12:23","extension":"png","order_by":2,"title":"Figure 2","display":"","copyAsset":false,"role":"figure","size":208610,"visible":true,"origin":"","legend":"\u003cp\u003ea) Schematic of Initial Tool-Workpiece Interaction Geometry in Drilling b)Lagrangian Mesh Morphology Showing Element Size Variation in Drill and Workpiece\u003c/p\u003e","description":"","filename":"2.png","url":"https://assets-eu.researchsquare.com/files/rs-7085345/v1/fe9a1e6f62365aa354714d8d.png"},{"id":87257147,"identity":"9c00a8c8-9e60-40cf-a780-63a0b1cc03f2","added_by":"auto","created_at":"2025-07-22 06:12:23","extension":"png","order_by":3,"title":"Figure 3","display":"","copyAsset":false,"role":"figure","size":89986,"visible":true,"origin":"","legend":"\u003cp\u003eprocedure of the numerical modeling of the chip formation\u003c/p\u003e","description":"","filename":"3.png","url":"https://assets-eu.researchsquare.com/files/rs-7085345/v1/09fb30998bb9c878f23ab817.png"},{"id":87258244,"identity":"7b56c155-81d2-412e-837d-d2fb88522972","added_by":"auto","created_at":"2025-07-22 06:36:23","extension":"png","order_by":4,"title":"Figure 4","display":"","copyAsset":false,"role":"figure","size":765914,"visible":true,"origin":"","legend":"\u003cp\u003eTemperature distributions (workpiece/tool contact) using a cutting speed of 300 m/min.\u003c/p\u003e","description":"","filename":"4.png","url":"https://assets-eu.researchsquare.com/files/rs-7085345/v1/8f45a7f59348be0a5295f57f.png"},{"id":87258042,"identity":"8c6c4879-dd11-4b5d-8a35-52bbc087d4a6","added_by":"auto","created_at":"2025-07-22 06:28:23","extension":"png","order_by":5,"title":"Figure 5","display":"","copyAsset":false,"role":"figure","size":779045,"visible":true,"origin":"","legend":"\u003cp\u003eTemperature distributions using a cutting speed 460m/min\u003c/p\u003e","description":"","filename":"5.png","url":"https://assets-eu.researchsquare.com/files/rs-7085345/v1/ed7dc17bc491fba7063738b3.png"},{"id":87257158,"identity":"f33b3cf8-dd1c-4d8e-9184-ed399b6bb698","added_by":"auto","created_at":"2025-07-22 06:12:23","extension":"png","order_by":6,"title":"Figure 6","display":"","copyAsset":false,"role":"figure","size":843827,"visible":true,"origin":"","legend":"\u003cp\u003eThe chip morphology using different cutting speeds: (a) 300 m/min and (b) 460 m/min.\u003c/p\u003e","description":"","filename":"6.png","url":"https://assets-eu.researchsquare.com/files/rs-7085345/v1/917be99b89bec50125c8ba39.png"},{"id":87257157,"identity":"ff80b0bd-68b7-4bb7-8feb-81aeb4847a45","added_by":"auto","created_at":"2025-07-22 06:12:23","extension":"png","order_by":7,"title":"Figure 7","display":"","copyAsset":false,"role":"figure","size":859997,"visible":true,"origin":"","legend":"\u003cp\u003eEquivalent stress distribution in tool / workpiece / chip contact a) c) and e) cutting speed Vc= 300m/min , b) d) and f) Cutting speed Vc = 460 m/min\u003c/p\u003e","description":"","filename":"7.png","url":"https://assets-eu.researchsquare.com/files/rs-7085345/v1/2eb30b6bc8c052e087dcafeb.png"},{"id":87258043,"identity":"cc2508e5-df6d-4aca-99a1-23b5bb85216c","added_by":"auto","created_at":"2025-07-22 06:28:23","extension":"png","order_by":8,"title":"Figure 8","display":"","copyAsset":false,"role":"figure","size":494504,"visible":true,"origin":"","legend":"\u003cp\u003eTemperature distribution across the entire tool.\u003c/p\u003e\n\u003cp\u003e\u003cbr\u003e\u003c/p\u003e","description":"","filename":"8.png","url":"https://assets-eu.researchsquare.com/files/rs-7085345/v1/e11c437b657e2152237442db.png"},{"id":87257326,"identity":"11f8a085-0a12-4eb5-a487-a29aaccd00c9","added_by":"auto","created_at":"2025-07-22 06:20:50","extension":"png","order_by":9,"title":"Figure 9","display":"","copyAsset":false,"role":"figure","size":34574,"visible":true,"origin":"","legend":"\u003cp\u003eThe normal probability plot of predicted value versus real values for temperature\u003c/p\u003e","description":"","filename":"9.png","url":"https://assets-eu.researchsquare.com/files/rs-7085345/v1/213abdbfb8d7daf6805ad2ef.png"},{"id":87257163,"identity":"a0261ea1-ecb5-45ac-ae31-851ecba3acdc","added_by":"auto","created_at":"2025-07-22 06:12:23","extension":"png","order_by":10,"title":"Figure 10","display":"","copyAsset":false,"role":"figure","size":251256,"visible":true,"origin":"","legend":"\u003cp\u003e3D plot of the cutting parameters against the temperature\u003c/p\u003e","description":"","filename":"010.png","url":"https://assets-eu.researchsquare.com/files/rs-7085345/v1/81c48de42f4dc2db3cb5e2cf.png"},{"id":92432099,"identity":"fa612d2a-58b9-43a2-845a-a9cbd0f3bb09","added_by":"auto","created_at":"2025-09-29 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