Exploring Tool Surface Temperature Distribution During Machining: Predictions and Solutions for Heat-Related Defects

Temperature distribution on the tool surface is a critical factor on tool lifespan reduction, wear, chatter, and selection of other machining parameters. Therefore, research and analysis in this area are necessary to identify and propose solutions for reducing tool surface temperature. In this study, examination and simulation of temperature distribution on the tool surface during the machining of various alloys such as aluminum, copper, carbon steel, and tungsten carbide have been presented. Next, the effects of factors such as tool angles, cutting speed, feed rate, and tool coating were investigated, and the predicted temperature distribution was also compared with experimental results. The findings revealed that appropriate coolant fluids can significantly reduce tool temperature, in addition increasing the friction angle between the tool flank and workpiece, End relief angel, and the Side rake angel have a considerable impact on reducing friction and ultimately tool temperature. Furthermore, by controlling parameters such as cutting speed, feed rate, and cutting depth, the amount of heat generated can also be managed. Furthermore, simulation results using Abaqus software on mild steel with a thermal conductivity of ۴۲.۶ W/(m·k), density of ۷۸۵۰ kg/m۳, and specific heat capacity of ۴۷۳ J/(kg·c°) predicted a tool surface temperature around ۷۸۶C°, while experimental infrared thermography showed a temperature of approximately ۷۶۰C°. Similarly, temperature distribution simulation on aluminum alloy ۲۰۲۴-T۳۵۱ with a thermal conductivity of ۱۷۷ W/(m·k), density of ۲۷۰۰ kg/m۳, and specific heat capacity of ۶۱۳ J/(kg·c°) demonstrated a temperature around ۲۵۵C°, while experimental thermocouple technique showed a temperature of approximately ۲۵۰C°.