Analysis of Contact Thermal Resistance and the Use of Coatings on Heat Transfer in Cemented Carbide Metal Cutting Tools

Abstract

Objective: The objective of this study is to investigate the thermal behavior of coated cutting tools in industrial turning processes, aiming to enhance machining efficiency and prolong tool lifespan.   Theoretical Framework: The study is grounded in the concepts of heat transfer, thermally insulating coatings, and their impact on cutting tool performance. Key theories and models include thermal conductivity, thermal insulation, and heat dissipation mechanisms.   Methodology: The research employs numerical simulation using the COMSOL® Multiphysics package to model transient heat transfer within coated tools and their holders. Thermal contact resistance at the tool-holder interface is also considered. Two coating configurations (Model 1 and Model 2) with different materials are analyzed, resulting in six simulation scenarios.   Results and Discussion: The simulations demonstrate significant temperature reductions in the coated tools compared to uncoated ones, with Model 2 showing the most substantial decrease. These findings indicate the effectiveness of thermally insulating coatings in mitigating heat generation and improving tool performance.   Research Implications: The study's findings have practical implications for the manufacturing industry, suggesting that the use of specific coatings can lead to higher cutting velocities and prolonged tool lifespan. These insights can inform decision-making in tool selection and process optimization.   Originality/Value: This research contributes to the literature by providing a detailed analysis of the thermal behavior of coated cutting tools under extreme temperatures. The study's innovative approach and practical implications offer valuable insights for improving machining processes and tool performance.