Modelling of temperature distribution in orthogonal machining using finite element method

This work employs finite element method (FEM) to model the temperature distribution of a mild steel with a carbide cutting tool insert in an orthogonal machining. The finite element model was simulated with MATLABTM and validated with experimental data. The temperature rise on the shear plane and the effect of different cutting parameters such as rake angles, cutting speed and forces were investigated. The results obtained were contour and surface plots at a bottom surface z = 0 and surface z = 0.02. It shows that the minimum and maximum temperatures of 200 and 400 K were recorded at the extreme end and tip of the tool respectively, due to high friction on the tip contact area, at the bottom surface z = 0. The minimum and maximum temperatures of 285 and 310 K at the extreme end and tip of the tool were recorded respectively, at a surface z = 0.02. In addition, it was observed that an increase in temperature caused an increase in cutting speed at different rake angles. Similarly, an increased in shear force caused an increase in temperature at different rake angles. The effect of thickness on temperature rise showed that the thinner the chip, the higher the temperature on the shear plane. It was evident that the maximum temperature occurred at the tool tip, as the temperature decreased with distance away from the tool tip. Consequently, the minimum temperature occurred at the extreme end of the tool.