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The impact of cutting temperature is one of the most important variables affecting the quality and performance of machined parts, as well as their tool life. Too hot, metal melts, and too cold, and the cutting edges deteriorate too quickly. Therefore, controlling the cutting temperature is critical for success in any metal cutting process.
There are a number of factors that can affect cutting temperature. These include cutting tool geometry, feed and speed, workpiece material, workpiece geometry, applied cutting forces, internal process cooling, and environmental parameters such as cutting fluid type and lubrication.
The geometry of the cutting tool has a major impact on cutting temperature. Different cutting tools have different rake and clearance angles, which directly affect the cutting temperature. A greater rake angle will reduce cutting temperatures by increasing the shear angle and reducing cutting forces. Similarly, a greater clearance angle will effectively block the chip flow and reduce cutting temperatures, as the chips are removed more slowly.
The material of the workpiece also plays an important role in cutting temperature. Especially when machining heat-resistant alloys (such as stainless steel and titanium), the cutting temperature tends to be much higher. Harder materials have higher cutting temperatures due to their higher strength and higher friction coefficient, while more ductile materials tend to have lower temperatures due to their lower strength and lower heat capacity.
Additionally, varying feed rates and cutting speeds will affect cutting temperature. Higher feed rates and speeds result in increased cutting forces, which generates higher temperatures. Conversely, lower feed rates and speeds can reduce cutting forces and cutting temperatures.
The shape of the workpiece is another important factor in cutting temperature. Devices with complicated geometries or non-uniform shapes are typically more difficult to machine. Inevitably, this means that higher surface temperatures will be generated. Similarly, narrow, deep pockets and especially cavities that are difficult to access and cool can result in local surface temperatures that are higher than those found during machining of flat surfaces.
Finally, Internal cooling can be used to reduce cutting temperatures. The cutting process is inherently exothermic, meaning that heat generated during the cutting process can cause it to become even hotter. To counter this, internal cooling systems are used in many machining centres. These cooling systems use high-pressure coolants like oil or water to cool the cutting edge and the workpiece, thus reducing surface temperature.
In conclusion, there are many factors that can affect cutting temperature. However, by understanding the impact of these factors and choosing the right tooling, materials, speeds and feeds, it is possible to reduce cutting temperature and improve machining performance.
