Finite element modelling of temperature distribution in the cutting zone in turning processes with differently coated tools

The aim of this study is to check the applicability of various simulation models to obtain finite element solutions of cutting forces, specific cutting energy and adequate temperatures for a range of coated tool materials and defined cutting conditions. Commercial explicit finite element code Thirdwave AdvantEdge has been used in simulations of orthogonal cutting processes performed by means of uncoated carbide and coated tools. The latter were equipped with progressively increasing number of thin layers including TiC, TiN and Al2O3 films deposited onto ISO P20 carbide substrates. Results showing the tool–chip interfacial friction influencing the temperature distribution fields, as the consequence of using coated tools, are the main and novel findings of this paper. The various thermal simulation results obtained were compared with the measurements of cutting temperature and discussed in terms of literature data.