A numerical approach to investigate the influence of cutting fluid on tool wear in machining AISI 1045 steel

Abstract

Abstract. The proposed work presents the development of a numerical model to take into account cutting fluids when turning of an AISI 1045 steel with a TiN coated tool. At this stage, the study considered the impact of a cutting fluid only based on its thermal properties and ability to reduce friction. Three heat exchange scenarios were explored: dry machining (h = 20 W.m-2.K-1), use of a straight oil lubrication with low pressure (h = 200 W.m-2.K-1) and cooling with an emulsion based lubrication (h = 1000 W.m-2.K-1). Regarding friction, three levels of static friction (µs = 0.3, 0.5 and 0.7) have been considered. Following an analysis of thermomechanical loads (stress, sliding speed, and temperature) exerted on the tool, a Usui wear law was employed for each case to simulate cutting tool wear. Results indicate that friction exerts a significant impact compared to the convection coefficient.