International Scientific Journal


This paper presents to develop first-order models for predicting the cutting temperature for end-milling operation of Hastelloy C-22HS by using four different coated carbide cutting tools and two different cutting environments. The first-order equations of cutting temperature are developed using the response surface methodology (RSM). The cutting variables are cutting speed, feed rate, and axial depth. The analyses are carried out with the aid of the statistical software package. It can be seen that the model is suitable to predict the longitudinal component of the cutting temperature close to those readings recorded experimentally with a 95% confident level. The results obtained from the predictive models are also compared with results obtained from finite-element analysis (FEA). The developed first-order equations for the cutting temperature revealed that the feed rate is the most crucial factor, followed by axial depth and cutting speed. The PVD coated cutting tools perform better than the CVD-coated cutting tools in terms of cutting temperature. The cutting tools coated with TiAlN perform better compared with other cutting tools during the machining performance of Hastelloy C-22HS. It followed by TiN/TiCN/TiN and CVD coated with TiN/TiCN/Al2O3 and TiN/TiCN/TiN. From the finite-element analysis, the distribution of the cutting temperature can be discussed. High temperature appears in the lower sliding friction zone and at the cutting tip of the cutting tool. Maximum temperature is developed at the rake face some distance away from the tool nose, however, before the chip lift away.
PAPER REVISED: 2012-04-16
PAPER ACCEPTED: 2012-05-02
CITATION EXPORT: view in browser or download as text file
THERMAL SCIENCE YEAR 2014, VOLUME 18, ISSUE Supplement 1, PAGES [S269 - S282]
  1. Matsumoto, Y., Barash, M.M., Liu, C.R., Effect of hardness on the surface integrity of AISI 4340 steel, J. Eng. Ind. Trans. ASME, 108 (1986), pp. 169-175.
  2. Dewes, R.C., Ng, E.G., Chua, C.K., Newton, P.G., Aspinwall, D.K., Temperature measurement when high speed machining hardened mould/die steel, J. Mater. Process. Technol., 92-93 (1999), pp. 293-301.
  3. Astakhov, V.P., Metal cutting mechanics, CRC press, 1999.
  4. Usui, K. , Shirakashi, T., Mechanics of machining from descriptive to predictive theory, on the art of cutting metals, ASME PED, 7 (1982), pp. 13 -35
  5. Tieu, A.K., Fang, X.D., Zhang, D., 1998, FE analysis of cutting tool temperature field with adhering layer formation, Wear, 214 (1982), pp. 252-258.
  6. Ng, E.G., Aspinwall, D.K., Brazil, D., Monaghan, J., Modelling of temperature and forces when orthogonally machining hardened steel, Int. J. Mach. Tools Manuf., 39 (1999), pp. 885-993.
  7. Soo, S., Aspinwall, D., Dewes, R., 3D FE modelling of the cutting of Inconel 718, J. Mater. Process. Technol., 150 (2004), pp. 116-123.
  8. Marusich, T. D., Effects of friction and cutting speed on cutting force, ASME MED23313, (2001), pp. 115-123.
  9. Marusich, T. D., Ortiz, M., Modeling and simulation of high-speed machining, Int. J. Num. Meth. Eng., 38 (1995), pp. 75-94.
  10. Stimimann, J., Kirchheim, A., New Cutting force Dynamometer for high precision machining, Industrial Tooling Conf., (1997), pp. 1-7.
  11. Ezugwu, E.O., Pashby, I.R., High speed milling of nickel-based superalloys, J. Mater. Process. Technol., 3 (1992), pp.429-437.
  12. Manjunathaiah, J., Endres, J.W., A new model and analysis of orthogonal machining with an edge-radius tool, Trans.ASME, J. Manufac. Sci.Eng., 122 (2000), pp. 384-390.
  13. Kennalmetal metal cutting catalogue (2007).
  14. Kadirgama, K., Abou-El-Hossein, K.A., Mohammad, B., Habeeb, H., Numerical and statistical model to determine temperature and heat distribution when machining HASTELLOY C-22HS, Inter. Bull. Stat. Eco., 1 (2007), pp. 24-41.
  15. Shen, G. Modelling the effect of cutting fluids in peripheral milling, PhD thesis (1996)
  16. Kitagawa, T., Kubo, A., Maekawa, K., Temperature and wear of cutting tools in high speed machining of Inconel 718 and Ti -6Al-6V-2Sn, Wear, 202 (1997), pp.142-148.
  17. Shaw, M.C., Metal cutting principles, Oxford University Press, New York, (1986).
  18. Korkut, I., Boy, M., Karacan, I., Seker, U., Investigation of chip-back temperature during machining depending on cutting parameters, Mater. Des., 28 (2007), pp. 2329-2335.
  19. Muraka, P.D., Barrow, G., Hinduja, S., Influence of the process variables on the temperature distribution in orthogonal machining using the finite element method, Int. J. Mech. Sci., 21 (1979), pp. 445-456.
  20. Lee, M., Horne, J.G., Tabor, D., 1979, The mechanism of notch formation at depth of cut line of ceramic tools machining nickel-base superalloys, Proc. 2nd Int. Conf., Wear Materials, Dearborn, MI, (1979), pp. 460-464.
  21. Warburton, P., Problems of machining nickel-based alloys, Iron and Steel Institute, Special Report, 94 (1967), pp. 151-160.
  22. Ezugwu, E.O., Machado, A.R., Pashby, I.R., Wallbank, J., The effect of high-pressure coolant supply, Lub. Eng., 47 (199), pp.751-757.
  23. Pfouts, W. R. 2000, Cutting edge coatings, Manufac. Eng., 125.
  24. Destefani, J., Cutting tools 101: coatings, Manufac. Eng., (2002).
  25. Kadirgama, K., Abou-El-Hossein, K.A., Force prediction model for milling 618 tool steel using response surface methodology, Am. J. Appl. Sci., 8 (2005), pp. 1222-1227.
  26. Kadirgama, K., Abou-El-Hossein, K.A. Torque and cutting force prediction model by using response surface method, Int. J. Appl. Math. Stat., 4 (2006), pp. 11-30.
  27. Tay, A.O., Stevenson, M.G., de Vahl Davis, G., Oxley, P.L.B., Using the finite element method to determine temperature distributions in orthogonal machining, Int. J. Mach. Tool Des. Res., 16 (1976), pp.335 - 349.
  28. Shih, A.J., Finite element analysis of orthogonal metal cutting mechanics, Int. J. Mach. Tools Manufact., 36 (1996), pp.255-273.
  29. Dogu, Y., Aslan, E., Camuscu, N., A numerical model to determine temperature distribution in orthogonal metal cutting, J. Mater. Process. Technol., 171 (2006), pp.1-9.
  30. Ozel, T. Investigation of high speed flat end milling process prediction of chip formation, cutting force, tool stresses and temperatures, PhD dissertation, (1998)
  31. Soo, S.L., Aspinwall, D.K., Dewesa, R.C., 3D FE modelling of the cutting of Inconel 718, J. Mater. Process. Technol., 150(2004), pp.116-123.

© 2019 Society of Thermal Engineers of Serbia. Published by the Vinča Institute of Nuclear Sciences, Belgrade, Serbia. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution-NonCommercial-NoDerivs 4.0 International licence