The fraction of heat generated in the primary shear zone that is conducted into the workpiece is a key factor in the calculation of the shear plane temperature and in calculating the cutting forces based on material flow stress. Accurate analytical, numerical, or experimental determination of this heat partition coefficient is not available to date. This study utilizes a new approach to obtain the heat partition coefficient for the primary shear zone using results for strain, strain rate, and temperature distribution obtained from a coupled thermo-mechanical finite element analysis of machining. Different approaches, using strain rate and equivalent strain, are used for calculating the total plastic power in the primary shear zone and the heat generated by plastic deformation below the plane of the machined surface. The heat carried away by the workpiece is obtained by calculating the heat flow by convection in regions where the conduction is expected to be small. We have used an elastic perfectly plastic material model and constant thermal properties to mimic the assumptions used in analytical models. The fraction of the total heat generated in the primary shear zone that is conducted into the machined workpiece is found and compared to the prediction of different analytical models. It is found that for most of the cutting conditions, the values of heat partition coefficient are closest to those provided by Weiner’s model.

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