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This paper analyzes heat flux transfer in the cutting tool in steady state orthogonal cutting. The method involves an iterative procedure to determine temperature distributions in the tool from varying heat flux transfer conditions. The temperature distributions determined from this procedure were compared with those obtained experimentally. A coincidence of the experimental and theoretical temperature distributions implied that the chosen heat flux model was appropriate. The experimental temperature distributions were obtained using a split carbide tip with special thermosensitive paint net. This prevented any split effect on the contact surfaces by films of any size and type. The investigation has provided two main insights. Firstly, it was apparent that the average temperatures determined from temperature models can be at large variance with those determined based on experimental observations. Thus, these models have to consider the effect of heat flux transfer peculiarity in the cutting tool if accurate predictions are desired. Secondly, it pointed to the necessity to account for such factors as heat flux reflection from tip sides, dependence of thermal properties on temperature and rise in temperature of the workpiece if accurate predictions are desired. It is demonstrated how the most accurate representation of heat transfer processes in the cutting tool can be determined through analyses based on accurate and reliable experimental temperature distributions.

A new system for on‐machine measurement of workpieces is described. The system is based on a fine touch sensor that enables the cutting tool itself to act as a contact probe to inspect the workpiece. The proposed measurement technology combines the Q‐setter with the fine touch sensor. This low cost measurement system is applied to automatic workpiece setup and improving workpiece dimensional accuracy on a CNC turning center. It is shown that using the proposed measurement system results in workpiece setting time decrease and workpiece machining accuracy improvement. The development of the on‐machine measurement system makes the fine touch sensor extremely attractive for CNC machine retrofitting.

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