The computation of cutting temperatures under flank-worn condition needs the knowledge of the forces due to flank wear and chip formation. Methods determining forces due to flank wear have been based on the assumption that the chip formation process remains constant as the tool flank is progressively worn, such that the force due to flank wear can be isolated from the total cutting force measured. This assumption continues to be used in literature despite the fact that there is evidence disproving it. Error introduced by this assumption for computing work surface temperature can be significant, as shown by the result of this paper.

In this study, the forces and temperatures due to flank wear were investigated using a newly developed thermal model and orthogonal hard turning experiments without the above assumption. First, the microstructural change in chips was used to determine the heat carried by the work and chip. Then the heat generated and the heat partition coefficients at both tool-work and tool-chip interfaces were obtained by solving the heat partition equations of the thermal model. Finally, shear forces at the tool-work interface and tool-chip interface that were coupled in the cutting process were determined independently without using cutting force measurement. The results also show that, as flank wear increases, the force due to flank wear determined by this method is larger and the interface temperatures are higher than those obtained based on the conventional assumption.

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