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Thermal influence analysis of coatings and contact resistance in turning cutting tool using COMSOL

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Abstract

In machining processes, cutting tools reach temperatures higher than 900 °C, thus deteriorating their mechanical properties. To reduce this problem, cutting tools are coated with materials possessing thermal insulation characteristics. Such coatings benefit machining, providing faster cutting speeds and tool life. However, the heating of the tools is still present. Therefore, in this work, an analysis of the thermal effects of coating in a carbide tool using COMSOL® software is presented. The effects of convection, radiation, and contact resistance between the tool and the tool holder are also considered. The thermophysical properties of the tool elements depend on temperature. Experimental measurements of parameters related to contact resistance were carried out to make the thermal model closer to real situations. The COMSOL program was used to solve the heat diffusion equation using the finite element method. Comparisons of calculated temperatures are presented for the uncoated (substrate only) and coated inserts with aluminum oxide (Al2O3) and titanium nitride (TiN), respectively. Coatings fulfill the role of protecting the heat directed to the tool substrate, but at different intensities. While the Al2O3 acts as a thermal barrier, retaining heat on the output surface, TiN has a less intense temperature gradient in the space of 10 μm, including a lower temperature on the output surface. The contact resistance raised the temperature on the output surface by 45.2 °C, 39.6 °C, and 39.5 °C for uncoated tools and coated by Al2O3 and TiN, respectively.

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Acknowledgements

The authors wish to thank CNPq, FAPEMIG, and CAPES for the financial support.

Availability of data and materials

The datasets generated and/or analyzed during the current study are available from the corresponding author on reasonable request.

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The founding sponsors had no role in the design of the study; in the collection, analyses, or interpretation of data; in the writing of the manuscript; and in the decision to publish the results.

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Authors and Affiliations

  1. Instituto de Engenharia Mecânica - IEM, Universidade Federal de Itajubá - UNIFEI, Campus Prof. José Rodrigues Seabra, Av. BPS, 1303, Itajubá, Minas Gerais, 37500-903, Brazil

    Carlos A. Corrêa Ribeiro, João R. Ferreira & Sandro M. M. Lima e Silva

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  1. Carlos A. Corrêa Ribeiro
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  2. João R. Ferreira
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  3. Sandro M. M. Lima e Silva
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Contributions

Carlos Adriano Corrêa Ribeiro: conceptualization, methodology, software, formal analysis, and writing; João Roberto Ferreira: resources and co-supervision; and Sandro Metrevelle Marcondes de Lima e Silva: resources, review, editing, and supervision.

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Correspondence to Carlos A. Corrêa Ribeiro.

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Corrêa Ribeiro, C.A., Ferreira, J.R. & Lima e Silva, S.M.M. Thermal influence analysis of coatings and contact resistance in turning cutting tool using COMSOL. Int J Adv Manuf Technol 118, 275–289 (2022). https://doi.org/10.1007/s00170-021-07835-4

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