A New Approach to Cutting Temperature Prediction Considering the Thermal Constriction Phenomenon in Multi-layer Coated Tools

A novel approach to the prediction of cutting temperature in multi-layer coated tools is presented. This approach considers the contact mechanics at asperity level and resulting thermal constriction resistance phenomenon. Micro-contact model was developed and the correlation between contact pressure and thermal constriction resistance of uncoated and multi-layer coated tools is established. The thermal interaction and redistribution of heat between the workpiece, the chip and the tool were analyzed, supported by FE model, which considers thermal characteristics of multi-layer coating. The results indicate that the tool coating may cause significant reduction in heat flowing into the tool.