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Dramatic variation of tool temperature while machining is treated as a considerable problem because it shortens the life of cutting edge which is considered as low durability of that part resulting in an adverse effect on the production. The excessive heat generated in the local cutting zone leads to thermal deformation, noticeable tool wear and low machining accuracy as well. In general, during highly precise machining operatios, it is necessary to determine the amount of process heat and heat fluxes into the work piece, tool and chips. This differs from various physical properties of tool including tool geometry, physical properties and for different operating conditions. Therefore, for precision machining operation it is discernible that the temperature distribution and the rate of cutting heat generation during the cutting operation are important for the prediction of thermal deformation. The aim of this research is to show an explicit overview of the nature of heat generation varying with different materials and cutting speed. In this study the cutting environment was designed in Solidworks Premium 2016 software and then it was simulated through Comsol Multiphysics using thermoelastic physics interface. The analysis was observed for aluminum and cast iron as job material and high speed steel as cutting tool. The result found during analysis was more heat generation in cast iron machining compared to aluminum. It was also determined that the total temperature field of job material during cutting process changes with simultaneous change in cutting speed and feed rate. The results certified the endeavor of making a comparison between two dissimilar materials for determining the optimum condition in production aspects. [ABSTRACT FROM AUTHOR]

The process of heat generation or absorption in metals under stress is caused by intermolecular interaction taken place after applying external force. Quantity of generated or absorbed heat depends on the magnitude of the applied force and the induced stress. The relationship between the heat and stress is one of the basic material property that determines the failure of that specific metal. So, it is important to know the relationship between the stress and formation of heat in material while designing a product. Two basic parameters, material property and induced stress, determine the quantity of generated or absorbed heat. Again, induced stress determines the fact if heat would be absorbed or be generated. No significant and to the point research work has been found about this subject, hence the aim of this study is to observe the generation of heat in different metals under different types of load condition. For the analysis, the chosen metals were Cast iron, Aluminum, AISI 4340 and Structural steel. These metals were chosen because of being widely used as engineering metals. The applied load conditions for the experiment were tension, compression and bending. The analysis was conducted using finite element technique in ComsolMultiphysics 5.3. The geometry of the metal was designed in Solidworks Premium 2016 and then imported in thermoelastic physics interface of ComsolMultiphysics. The loading conditions were varied to determine the relationship between the stress and generated heat and later compared with each other. The results show that the rate of generation of heat for AISI 4340 is greater than other metals at its ultimate strength. The temperature distribution shows that, the dissipation of temperature throughout the specimen is greater in aluminum than other three metals. These results will be useful in choosing metals that are to be used for fabricating devices employed in dynamic load condition. [ABSTRACT FROM AUTHOR]