Analysis of transient average tool temperatures in face milling

The increased tool temperature has great effect on tool life, machining efficiency and even the quality of the products in face milling. The objectives of this study are to predict the transient average tool temperatures under different cutting conditions with fixed cutting velocity and metal removal rate, and investigate the evolution of tool temperature with cutting condition. Finite element simulations of orthogonal metal cutting are performed so as to predetermine the evolution process of the heat source on the tool rake face. An analytical model is proposed to calculate and analyze the tool temperatures under nine different cutting conditions. The results reveal that the minimum transient average tool temperature can be acquired by adopting suitable cutting condition. The proposed theoretical method provides insight into the complex evolution of tool temperatures. It also provides information for the search for the optimum cutting condition under which the longest tool life can be obtained.