Estimated Cutting Temperatures—Their Use as a Predictor of Tool Performance When Machining Plain Carbon Steels

A theory of machining which takes account of the dynamic flow stress and temperature properties of the work material, and which has been modified to take advantage of recent information concerning the average values of the distributed heat sources at the tool wearing surfaces, has been applied to the prediction of cutting forces, temperatures, etc., when machining plain carbon steels with carbide cutting tools. The temperatures obtained from this theory are used together with extensive experimental data to examine the relationship between tool wear rate and cutting temperatures for a range of tool materials, work materials and cutting conditions. It is shown that, within the variability of the experimental data, for a given tool material/work material combination, the logarithm of the tool wear rate is a linear function of the reciprocal of the estimated tool temperature. This is indicative of a temperature dependent wear mechanism, and the wear rate/temperature results are discussed in terms of diffusion behaviour. The possible advantages of applying such an approach to the estimation of tool life for application in industrial machining operations is considered.

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