Design and analysis of an internally cooled smart cutting tool for dry cutting

Abstract

Cutting fluid is traditionally used to remove heat generated during the cutting process, but it can cause environmental pollution, health hazards, and high cost of production. Dry cutting, without using the cooling liquid, is thus desirable and promising for the machining industry to produce components and products, both ecologically and more economically. In this paper, an internally cooled cutting tool for dry cutting is presented as a temperature-sensored smart cutting tool in its own right, with further applications for adaptive machining purposes. The cutting tool is characterized by a simple changeable internal cooling structure near the cutting tip. Simulations were performed to study the theoretical cooling efficiency and to optimize the cooling structure by combining it with the Taguchi Method. Furthermore, cutting trials were carried out to validate the novel cutting tool experimentally.

State of art of cooling method for dry machining

“…Traditionally, in wet machining, cutting fluid is used to reduce cutting temperature, reduce cutting force, minimize formation of buildup edge and improve tool life [1,2]. In USA alone, volume of cutting fluid that is been discharged is nearly 115 million liters per year [3] and cost to retreat the cutting fluid with additive is USD 15 per gallon [3].…”

“…Meanwhile, cutting fluid also creates environmental issues and causes health injuries to humans [6,7]. Exposure of cutting fluid causes skin cancer and evaporation of cutting fluid at cutting zone is dangerous to human respiratory system [1,6]. Cutting fluid cannot be used for long term as it is tend to wear out after mixing with the chips [4].…”

“…The main limitation in dry machining is the heat generation at cutting tool specifically; cutting zone. During machining, friction and chip deformation at cutting interface causes thermal load which causes high temperature at cutting tool [1,2]. High temperature is because of the high friction and adhesion formation at cutting tool [1].…”

“…During machining, friction and chip deformation at cutting interface causes thermal load which causes high temperature at cutting tool [1,2]. High temperature is because of the high friction and adhesion formation at cutting tool [1]. Heat generated during machining causes two changes in the cutting tool; reduces mechanical and wear resistance [4].…”

“…This leads to the tool wear subsequently which reduces the tool's life span [2]. Formation of tool wear causes the workpiece subjected to poor surface roughness and less dimensional accuracy [1,2]. There are two methods to control the heat generated during machining; limitation of cutting parameter and usage of cutting fluid [4].…”