Method for Determining Contact Temperature of Tool Rake Face During Orthogonal Turning of Ti-6Al-4V Alloy

This paper proposes a method for determining the contact temperature in the secondary shear zone. The input data include the results of the experimental tests of the orthogonal turning of a Ti-6Al-4V titanium workpiece using uncoated WC-Co tools with a flat rake face. The cutting force components were recorded using a piezoelectric dynamometer, a thermovision camera was used to record the temperature in the cutting zone, and a high-speed camera was used to record the chip-forming process. The independent variables included machining parameters, feed rate, cutting speed, and rake angle. A dual-zone thermomechanical cutting process model that accounted for the sticking and sliding areas was adapted for the identification of the heat flux in the chip-rake face contact zone. Then, based on the Shaw approach, the partition coefficients were determined for the contact temperature on the chip-tool tip contact. In addition, the results of the experimental tests allowed the determination of the relationship among the process parameters, friction coefficients, and the length of the contact of the chip with the tool rake face. A graphical visualization of the temperature distribution on the tool rake face was performed using the MATLAB PDE 3.9 software package. Although the application of the dual-zone model has been well presented in the literature, the results provided in this paper may be helpful in analyzing and modeling thermal phenomena in the secondary shear zone.