On the analysis of chip temperature distribution in orthogonal machining

Analytical methods of solution for the chip temperatures including those along the shear plane and the tool/chip interface have been developed for typical cases of orthogonal machining with a continuous chip. To make the model more realistic, the shear plane is made to be inclined with the chip velocity, as generally occurs. It is shown that this geometrical condition can be relaxed, which results in considerable mathematical simplification. It is found that the temperature distributions along the chip back (chip/air interface) taken directly from experiments by an infra-red thermo-tracer can be best used for verification of previous models. The experimental data are seen to seriously disagree with the previous results near the interface of chip/work free surface. It is also found that consistent predictions of these temperatures can be made by introducing a more realistic boundary condition into the analytical model.