3D Numerical Simulation and Optimization of Heat Transfer in High-Speed Drilling of XC48 Steel

In this study, a numerical approach based on thermal analysis of the cutting tool/workpiece contact is developed. The objective is to understand the thermomechanical phenomena caused by the high temperature within the cutting tool/workpiece contact during high-speed drilling.A novel methodology is proposed to determine the temperature distribution in the different cutting areas, considering heat distribution as a function of time, which is challenging to measure experimentally. The simulation results are expected to help in predicting machining uncertainties, particularly for steel, one of the widely used materials in industry.A mathematical study is conducted to model the temperature using the design of experiments (DoE) method. The second part of this work aims to optimize the cutting parameters and to analyze the influence of these conditions on the machining process. The objective is to identify which temperature values contribute to minimizing tool wear, thereby extending the tool's service life.This model enables reliable prediction of the average interface temperature between the chip, workpiece, and tool during the drilling of the XC48 steel.