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Introduction
Cutting is a method used to shape parts out of metal and other materials. The process removes excess material and establishes the desired shape. The most common means of metal cutting are machining operations, such as machining centers, turning centers, drills, and milling machines. In order to achieve a successful, correct cutting operation, a number of factors must be considered. These include, but are not limited to, the type of cutting tool being used, the speed of the cutting tool, the feed rate, and the workpiece material. Combinations of these factors can create cutting forces and temperatures which can compromise the cutting process and the finished part.
Types of Cutting Heat
Cutting heat is the thermal energy generated during a cutting operation. Two types of cutting heat are generated: frictional heat and cutting zone heat. Frictional heat is the energy produced as a result of the sliding contact of the cutting tool against the workpiece material. Cutting zone heat is the thermal energy created in the area between the cutting tool and the workpiece due to the extreme pressure and confinement of the cut and the rapid shearing of the material being machined.
Frictional Heat
Frictional heat is the result of the mechanical extrusion of material along the cutting edge of the tool during the cutting process. During this process, the tool is forced against the workpiece and friction is generated, increasing cutting temperatures. The frictional heat can be reduced by reducing the contact area between the cutting tool and the workpiece. This can be done by decreasing the cutting tool speed, increasing the feed rate, or lubricating the cutting zone with a coolant. Another way to reduce frictional heat is by minimizing the cutting forces applied to the tool.
Cutting Zone Heat
Cutting zone heat is the heat generated in the cutting zone as a result of the extreme pressure and confinement of the cut as well as the rapid shearing of the material being machined. This type of heat is commonly associated with milling operations and is affected by the rate at which material is removed and the cutting conditions used. The cutting parameters used to reduce frictional heat can also be used to reduce the cutting zone heat. Additionally, using a tool material with a higher heat resistance, such as carbide, and keeping the cutting tools sharper are also effective ways to reduce cutting zone heat.
Conclusion
Cutting is a complex process and a number of factors must be taken into account in order to achieve a successful cutting operation. Heat is one of the most important factors to consider when cutting, as it can greatly affect the end result. Frictional heat and cutting zone heat can both be generated during the cutting process, and it is important to minimize them in order to ensure a good quality cut. Doing so involves implementing proper cutting parameters and tool materials, as well as making sure the cutting tools are sharp.
