Numerical and Experimental Calibration of a Friction Model considering Heat transfer

In the machining of safety-critical components made from nickel-based alloys, ceramic cutting tools are widely used due to their high performance at elevated cutting speeds and process-induced temperatures. A key challenge in simulating thermal loads during machining arises from the need to model friction behavior and the resulting heat transfer at the tool–workpiece interface. Therefore, this study presents the calibration of a friction model in combination with a contact heat transfer model. To this end, high-speed friction experiments up to 500 m/min were carried out on a lathe. Thermographic and pyrometric measurements were used to capture surface temperature fields, while cutting forces were recorded using a dynamometer. The friction and heat transfer parameters were calibrated using an inverse approach based on finite element simulations utilizing a 3D Lagrangian model. The calibration accounted for the effects of relative speed, temperature, and contact pressure. The results demonstrate that the developed model enables accurate estimation of friction coefficients, with a mean error margin of 7 %, under high relative speeds and normal forces. Moreover, the calibrated heat transfer coefficient enables the estimation of friction-induced temperature rise in the workpiece. This methodology provides a basis for the simulation of thermomechanical loads in machining processes involving ceramic tools.