Investigation of temperature distribution in orthogonal cutting through dual-zone contact model on the rake face

A two-dimensional analytical model to calculate the temperature distribution in orthogonal cutting with dual-zone contact on the rake face is presented. The study considers heat generation in the primary shear zone and on the rake face. The material behavior in the primary shear zone is represented by Johnson-Cook constitutive equation while the contact on the rake face is modeled by sticking and sliding friction zones. This new temperature distribution model is used to determine the maximum temperature on the rake face and two-dimensional temperature distribution in the chip and on the tool surface. The dual-zone contact model on the rake face and convection boundary condition on the flank face are the important contributions of this work. The simulation results of the developed model are compared with experimental results where a good agreement is demonstrated.