Modelling the Effects of Friction on Tool-Chip Interface Temperature During Orthogonal Cutting of Al6061-T6 Aluminium Alloy

In this work, finite element simulations based on the analytical model derived with the MATLAB software were used to establish the temperature fields within the cutting tool and tool-chip interface. The average tool-chip interface temperature model was simulated and the simulation results were compared with experimental results for validation. At a maximum cutting speed of 90 m/min, the maximum temperature obtained from the experiment was 410 oC, at same rake angle of 0o. However, the developed model predicted 490 oC under the same conditions. The higher value obtained by the model can be attributed to the negligence of heat losses to the surrounding by both convection and radiation modes, as an assumption in the formulated model. A similar trend of these results was also recorded for the case of rake angle and feed rate of 30o and 0.0635 mm/rev, respectively. It was observed that the simulation results and experimental measurements for the average tool-chip interface temperature agreed significantly.