Thermal modeling for white layer predictions in finish hard turning

Abstract Part thermal damage is a process limitation in finish hard turning and understanding process parameter effects, especially, tool wear, on cutting temperatures is fundamental for process modeling and optimization. This study develops an analytical model for cutting temperature predictions, in particular, at the machined-surfaces, in finish hard turning by either a new or worn tool. A mechanistic model is employed to estimate the chip formation forces. Wear-land forces are modeled using an approach that assumes linear growth of plastic zone on the wear-land and quadratic decay of stresses in elastic contact. Machining forces and geometric characteristics, i.e. shear plane, chip–tool contact, and flank wear-land, approximate the heat intensity and dimensions of the shear plane, rake face, as well as wear-land heat sources. The three heat sources are further discretized into small segments, each treated as an individual rectangular heat source and subsequently used to calculate temperatures using modified moving or stationary heat-source approaches. Temperature rises due to all heat-source segments are superimposed, with proper coordinate transformation, to obtain the final temperature distributions due to the overall heat sources. All heat sources are simultaneously considered to determine heat partition coefficients, both at the rake face and wear-land, and evaluate the final temperature rises due to the combined heat-source effects. Simulation results show that, in new tool cutting, maximum machined-surface temperatures are adversely affected by increasing feed rate and cutting speed, but favorably by increasing depth of cut. In worn tool cutting, flank wear has decisive effects on machined-surface temperatures; the maximum temperature increases 2–3 times from 0 to 0.2 mm wear-land width. White layers (phase-transformed structures) formed at the machined-surfaces have been used to experimentally validate the analytical model by investigating tool nose radius effects on the white layer depth. The experimental results show good agreement with the model predictions. The established model forms a framework for analytical predictions of machined-surface temperatures in finish hard turning that are critical to part surface integrity and can be used to specify a tool life criterion.