Machinery & Energetics

Modelling and studying of thermal behaviour of thin layer using finite element method – application to coated tools

Abdelhak Saoudi, Belkacem Meddour, Badis Haddag, Mohammed Salah Aggoune, Abdelaziz Abboudi
Download article
Abstract

The continuous evolution of thin-layer technologies is essential in modern dry machining, where effective thermal control of coated cutting tools is critical for limiting heat-induced wear and extending tool life. The purpose of this article was to investigate and model the thermal response of coated cutting tools and to evaluate the influence of single-layer and multilayer thin coatings on heat transfer during orthogonal dry cutting. To achieve this objective, a transient thermal model based on the finite element method was developed using a Galerkin formulation combined with an implicit Crank-Nicolson time integration scheme. The numerical framework was applied to three tool configurations: an uncoated WC-Co insert, a TiN-coated insert, and a TiN/Al₂O₃ double-coated insert. Experimental dry turning tests were conducted to validate the numerical predictions. The results showed that the numerical model accurately reproduced the temporal evolution of temperature at the tool–chip interface and within the insert. The uncoated tool exhibited rapid heat penetration and pronounced internal thermal gradients. The TiN coating slightly increased the surface temperature but offered limited resistance to heat diffusion. In contrast, the TiN/Al₂O₃ multilayer configuration significantly restricted heat transfer towards the substrate, leading to lower internal temperatures and reduced thermal gradients. The Al₂O₃ layer acted as an effective thermal barrier, confining heat near the cutting edge and protecting the tool core from excessive thermal loading. These findings demonstrated that multilayer ceramic coatings provided superior thermal protection compared with single-layer coatings. The proposed finite element method approach could be effectively applied to coating design, tool optimisation, and thermal management in dry machining applications

Keywords

dry machining, heat transfer, numerical approach, cutting, temporal

Suggested citation
Saoudi, A., Meddour, B., Haddag, B., Aggoune, M.S. , & Abboudi, A. (2025). Modelling and studying of thermal behaviour of thin layer using finite element method – application to coated tools. Machinery & Energetics, 16(4), 53-63. https://doi.org/10.31548/machinery/4.2025.53
References
  1. Afazov, S.M., Ratchev, S.M., & Segal, J. (2010). Modelling and simulation of micro-milling cutting forces. Journal of Materials Processing Technology, 210(15), 2154-2162. doi: 10.1016/j.jmatprotec.2010.07.033.
  2. Ala, M., Liu, W., Liu, H., & Wang, F. (2025). Investigation of cladding track geometry using thermal finite element method in laser cladding additive manufacturing. The International Journal of Advanced Manufacturing Technology, 138, 4593-4614. doi: 10.1007/s00170-025-15804-4.
  3. Albrecht, P. (1960). New developments in the theory of the metal-cutting process: Part I. The ploughing process in metal cutting. Journal of Engineering for Industry, 82(4), 348-357. doi: 10.1115/1.3664242.
  4. Bencheikh, I., Bilteryst, F., & Nouari, M. (2017). Modelling of the thermomechanical behaviour of coated structures using single and multi-level-set techniques coupled with the eXtended Finite Element Method. Finite Elements in Analysis and Design, 134, 68-81. doi: 10.1016/j.finel.2017.06.001.
  5. Brito, R.F., de Carvalho, S.R., Marcondes de Lima e Silva, S.M., & Ferreira, J.R. (2009). Thermal analysis in coated cutting tools. International Communications in Heat and Mass Transfer, 36(4), 314-321. doi: 10.1016/j.icheatmasstransfer.2009.01.009.
  6. Grzesik, W., Bartoszuk, M., & Nieslony, P. (2005). Finite difference method-based simulation of temperature fields for application to orthogonal cutting with coated tools. Machining Science and Technology, 9(4), 529-546. doi: 10.1080/10910340500398258.
  7. Ifis, A., Bilteryst, F., & Nouari, M. (2013). Transient thermomechanical analysis of thin layers using a hybrid “MAX-FEM” model. Finite Elements in Analysis and Design, 69, 73-87. doi: 10.1016/j.finel.2013.01.008.
  8. Ipilakyaa, T.D., Tuleun, L.T., & Injor, O.M. (2024). Heat transfer modelling of multilayer coated tools during turning of H13 hardened steel: Analogous coating layer approach. Saudi Journal of Engineering and Technology, 9(4), 205-213. doi: 10.36348/sjet.2024.v09i04.002.
  9. Komanduri, R., & Hou, Z.B. (2001). Analysis of heat partition and temperature distribution in sliding systems. Wear, 251(1-12), 925-938. doi: 10.1016/S0043-1648(01)00707-4.
  10. Kone, F., Czarnota, C., Haddag, B., & Nouari, M. (2011). Finite element modelling of the thermo-mechanical behavior of coatings under extreme contact loading in dry machining. Surface and Coatings Technology, 205(12), 3559-3566. doi: 10.1016/j.surfcoat.2010.12.024.
  11. Kumar, C.S., Zeman, P., & Polcar, T. (2020). A 2D finite element approach for predicting the machining performance of nanolayered TiAlCrN coating on WC-Co cutting tool during dry turning of AISI 1045 steel. Ceramics International, 46(16), 25073-25088. doi: 10.1016/j.ceramint.2020.06.294.
  12. Kumaran, G., Sivaraj, R., Prasad, V.R., Beg, O.A., Leung, H.H., & Kamalov, F. (2021). Numerical study of axisymmetric magneto-gyrotactic bioconvection in non-Fourier tangent hyperbolic nano-functional reactive coating flow of a cylindrical body in porous media. The European Physical Journal Plus, 136(11), article number 1107. doi: 10.1140/epjp/s13360-021-02099-z.
  13. Lazoglu, I., & Altintas, Y. (2002). Prediction of tool and chip temperature in continuous and interrupted machining. International Journal of Machine Tools and Manufacture, 42(9), 1011-1022. doi: 10.1016/S0890-6955(02)00039-1.
  14. Nguyen, D.H., Bilteryst, F., Lazard, M., Lamesle, P., & Dour, G. (2008). Coupling of the eXtended Finite Element Method and the matching asymptotic development in the modelling of brazed assembly. International Journal of Material Forming, 1, 1119-1122. doi: 10.1007/s12289-008-0176-z.
  15. Rosa, P.A.R., Kolednik, O., Martins, P.A.F., & Atkins, A.G. (2007). The transient beginning to machining and the transition to steady-state cutting. International Journal of Machine Tools and Manufacture, 47(12-13), 1904-1915. doi: 10.1016/j.ijmachtools.2007.03.005.
  16. Sahoo, P., Patra, K., Singh, V.K., Gupta, M.K., Song, Q., Mia, M., & Pimenov, D.Y. (2020). Influences of TiAlN coating and limiting angles of flutes on prediction of cutting forces and dynamic stability in micro milling of die steel (P-20). Journal of Materials Processing Technology, 278, article number 116500. doi: 10.1016/j.jmatprotec.2019.116500.
  17. Schnaubelt, E., Wozniak, M., & Schöps, S. (2023). Thermal thin shell approximation towards finite element quench simulation. Superconductor Science and Technology, 36(4), article number 044004. doi: 10.1088/1361-6668/acbeea.
  18. Upadhyay, C., Rajput, S.S., Bera, S., Ju, H., Bhide, R., & Gangopadhyay, S. (2025). Influence of TiAlN coating thickness in dry machining of AISI 1045 steel using Finite Element simulation and experiments. Surface and Coatings Technology, 495, article number 131496. doi: 10.1016/j.surfcoat.2024.131496.
  19. Van Luttervelt, C.A., et al. (1998). Present situation and future trends in modelling of machining operations progress report of the CIRP Working Group ‘Modelling of machining operations’. CIRP Annals, 47(2), 587-626. doi: 10.1016/S0007-8506(07)63244-2.
  20. Zhang, J., Zhang, G., & Fan, G. (2022). Effects of tool coating materials and coating thickness on cutting temperature distribution with coated tools. International Journal of Applied Ceramic Technology, 19(4), 2276-2284. doi: 10.1111/ijac.14038.