ALE Simulation of Orthogonal Cutting: a New Approach to Model Heat Transfer Phenomena at the Tool Chip Interface

This paper presents a new procedure to evaluate the global heat transfer coefficient in orthogonal cutting. The
knowledge of the actual heat transfer conditions is a fundamental issue as far as the life, tool wear and tool
substitution interval are regarded. More in detail, an Arbitrary Lagrangian-Eulerian approach was utilised to
model orthogonal cutting process and the numerical simulations were validated by making experimental tests
for identifying cutting forces and internal tool temperatures. A mild steel was cut utilising both an uncoated
(WC) and a coated (TiN) tool. On the basis of both experimental and simulative data, a consistent model of
the global heat transfer coefficient as function of the local pressure and temperature at the tool-workpiece
interface was developed.