Wear 286–287 (2012) 108– 115 Contentslists availableat ScienceDirect Wear j o u r n a l h o me p a g e : w w w . e l s e v i e r . c o m / l o c a t e / w e a r Experimental characterization of friction coefficient at the tool–chip–workpiece interfaceduring dry cutting of AISI 1045 H. Ben Abdelali a,b,c,∗ , C. Claudin a , J. Rech a , W. Ben Salem b , Ph. Kapsa c , A. Dogui b a Université deLyon,EcoleNationaled’Ingénieurs deSaint-Etienne, Laboratoire deTribologie et Dynamique desSystèmes, UMR CNRS5513, 58 RueJeanParot, 42023Saint-Etienne, France b EcoleNationaled’Ingénieurs deMonastir,Laboratoire deGénie Mécanique, Avenue Ibn Al-Jazzar,5019Monastir,Tunisia c Université deLyon,EcoleCentrale deLyon,Laboratoire deTribologie et Dynamique desSystèmes, UMR CNRS5513, 36 Avenue GuydeCollongue, 69134Ecully, France a r t i c l e i n f o Articlehistory: Received11 November2010 Receivedin revisedform 13 May 2011 Accepted19 May 2011 Available online 27 May 2011 Keywords: Friction Sliding velocity Cutting Heat partition a b s t r a c t This paper presentsthe applicationof an experimentalset-up able to simulate similar tribological phe- nomena as the ones occurring at the tool–chip–workpiece interface in metal cutting. Especially, this systemenablesto reach contact pressuresup to 3 GPa and sliding velocitiesbetween 0 and 300m/min. In addition to classicalmeasurements of friction coefficients, the systemprovides information about the heat flux transmittedto pins, which enablesto estimatethe heat partition coefficientalongthe interface. This systemhas been applied to the characterizationof the tool–chip–workpiece interface during dry cutting of an AISI 1045 steel with TiN coated carbide tools. It has been shown that the sliding veloc- ity is the most influential parameterwhereas contact pressure has only a limited influence. However, three friction regimescan be distinguished.In the first regime (low sliding velocity),friction coefficient is almost constant whereas heat flux transmitted to cutting tools is proportional to sliding velocity. In the second regime (intermediatesliding velocity), friction coefficient decreases very significantly with sliding velocity whereas heat flux remains almost constant.In the third regime (high sliding velocity), friction coefficient is not affectedby sliding velocity whereas heat flux transmitted to the cutting tools increases again. © 2011 Elsevier B.V. All rights reserved. 1. Introduction In the context of global competition, companies from all countries are compelled to improve their productivity. As a conse- quence,they must optimize their production processesincluding metal cutting operations. In order to achieve this aim, industry adopts very high cutting regimes (high cutting speeds and feed rates). Under severe conditions, caused by a high cutting regime, the mechanical stressesand temperaturesat the tool–chip inter- face and near the cutting edge can be critically high, resulting in excessivetool wear or even premature tool failure. Therefore, it is necessary to develop accurate cutting process simulations to identify optimum cutting conditions in terms of tool materials, tool geometriesand coatings in order to sustain the productivity improvement in machining operations. The ‘cutting’ scientific community aims at improving the fundamental understanding of frictional phenomena occurring ∗ Correspondingauthor at: EcoleNationaled’Ingénieurs de Monastir, Laboratoire de GénieMécanique,AvenueIbn Al-Jazzar, 5019Monastir, Tunisia. Tel.: +216 22 679 661; fax: +216 73 505 866. E-mail address: hamdi.benabdelali@yahoo.fr (H. Ben Abdelali). at the tool–chip interface (‘secondary shear zone’) and at the tool–workpiece interface (‘rubbing zone’) in order to achieve an accurate modeling by means of finite element methods (Fig. 1) [1]. So far, the Coulomb model with a constant friction coeffi- cient, irrespective of the temperatureand the pressure,is usually used to describethe friction phenomenaat these interfaces.How- ever, in metal cutting, a wide range of cutting speeds is used (60–600 m/min) [2]. The temperatureat interfacesis directly influ- enced by the friction velocity. Moreover, the sliding velocities in the rubbing zone and in the secondaryshear zone are very much different. As a consequence, the rangeof temperatureis very large as shown by infrared measurementsat the tool–chip–workpiece interface by Rech [3]. The pressurealong the interface is also very different as reportedby Trent [4], valuesup to 2 GPa are mentioned [2]. Both temperatureand pressureare well known to have a great influence on the frictional behaviour. Thus, the assumption of a constant friction coefficient along the interfaceis not appropriate. In order to investigate the tribological phenomena at these interfaces,scientists consider two approaches. The first approach consists of using the cutting process itself [5–7]. The second one consists in using laboratory tests [8–12]. The first approach has been used by several researchers.The investigationsare usually basedon turning tests of a tube made of 0043-1648/$– seefront matter ©2011 Elsevier B.V. All rights reserved. doi:10.1016/j.wear.2011.05.030