High Speed Machining (HSM) is associated with higher cutting velocities and table feedrates and higher material removal rate, lower cutting forces in contrast to conventional machining. HSM can be undertaken dry or near dry and hence it is considered as environmentally friendly machining in relation to the use of cutting fluids. A key challenge in HSM is that, the thermal loads generated during the cutting process can be a major driver of thermally activated wear mechanism and hence affect machining performance. The ability of cutting tools to act as thermal barrier can be a highly desirable property for dry and HSM. Recently, research work has been conducted on laboratory based coated cutting tools to model and understand the fraction of heat that enters the cutting tool. These studies have shown the potential for TiN and TiAlN coated tools in reducing heat partition to the cutting tool when compared to uncoated tools. This PhD extended this work to modelling and characterising the heat partition for new generation commercial coated cutting tools considering tools from major insert manufactures. For this study commercial coated carbide tools were classified into two groups. In one group were coatings uniformly applied on both rake and flank faces of the insert (SERIES). The second group were tools that had different top coats for the rake and flank faces (Functionally Graded). This concept of functional grading is used to tailor the coating selection to the conditions that exist on a tool face. Moreover, the issue of restricted chip contact was modelled and clarified in terms of its impact on heat partition. This chip breaker design is of particular importance to inserts used for machining ductile materials. Thus the PhD has applied research methods to industrial cutting tools and helped elucidate the important aspects relating to the design, layout and selection of multilayer coatings. The heat partition was quantified by using a combined Finite Element (FE) and experimental approach. This methodology was applied by taking into consideration the appropriate friction phenomena during HSM i.e. sticking and sliding. A restricted contact length with groove profile geometry was considered for the application of heat load in the FE model. Orthogonal and external turning of AISI/SAE 4140 medium carbon alloy steel was conducted over a wide range of cutting speeds. An infrared thermal imaging camera was used to measure cutting temperatures. The results show that the layout of the coating can significantly affect the heat distribution into the cutting tool, specifically; the top coat can alter the friction conditions between the tool-chip contact. The distribution of heat (heat partition) into the cutting tool insert with the thickest layer of Al2O3 as a top coating is the lowest in the entire range of cutting speeds tested i.e. 10.5% at lower cutting speed and reduced to 3.4% at highest cutting speed. Investigations were also conducted to quantify the contribution of heat from the primary and secondary deformation zones using a combination of finite element modelling, analytical modelling and experimental data. The results deduced that the primary deformation zone heat source contributes 9.1% (on average) to the heat partition into the cutting tool. The contribution of the Thesis should be of interest to those who design, manufacture and coat cutting tools. It defines heat partition values for commercial coated carbide tools, assesses the requirements for multilayer design of thermally insulating cutting tools, the selection of coating top layer coats and the role of contact phenomenon on heat partition in dry and HSM of steels.

Titanium and its alloy (Ti-6Al-4V) are widely used in aerospace industries because of their light weight, high specific strength, and corrosion resistance. This study conducted a comparative experimental analysis of the machinability of Ti-6Al-4V for conventional flood coolant machining and sustainable dry machining. The effect of cutting speed, feed rate, and depth of cut on machining performance has been evaluated for both conditions. The machining time and surface roughness were found to be lower in dry machining compared to flood coolant machining. The tool wear was found to be unpredictable, and no significant difference was observed for dry and coolant machining. In a comparison of all the parameters, sustainable dry machining was found to provide better performance in machining Ti-6Al-4V. This study also investigated the machinability of Ti-6Al-4V using coated and uncoated tungsten carbide tools under dry conditions. Tool wear is a serious problem in the machining of titanium alloys in dry conditions. Heat dissipation from the toolworkpiece interface a difficult challenge in dry machining, resulting in the alloying of the workpiece to the tool surface. Dry machining with the coated tool was comparatively faster, and resulted in less tool wear than uncoated tools. Using the Titanium aluminum nitride TiAlN coated carbide tool during dry machining provided a smoother surface finish with lower average surface roughness. The conclusion, therefore, is that the tool coating was found to be effective for the dry machining of titanium alloys.