Implementation of exact thermal analysis in extended Oxley’s predictive machining theory

Finding the exact solution to the generated temperatures that are more closely aligned with the actual nature of the process is important while conducting analytical modeling of the chip formation process in metal cutting. The extended Oxley’s predictive machining theory is implemented with the exact thermal analysis approach. This study presents temperature distributions near the shear plane on the workpiece side along with an exact temperature prediction for orthogonal cutting using the Komanduri-Hou model for the shear plane heat source. An explicit solution is also derived to obtain the tool-chip interface temperatures. The intricate formulae utilized in the original research study of Komanduri-Hou are solved using MATLAB code. The approach used here makes it easier to use the exact solution in future research for various categories of materials. The temperature distribution plots help to clarify the metal-cutting procedure and understand the different heat zones. The outcomes of shear angle, forces, stresses, strains, strain rates, and average temperatures are consistent with those reported in earlier studies.