Investigation on an Innovative Internally Cooled Smart Cutting Tool with the Built-in Cooling-Control System

Öztürk, Erkan; Yıldızlı, Kemal; Sağlam, Fatih

doi:10.1007/s13369-020-05002-7

Cited by 17 publications

(20 citation statements)

References 28 publications

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“…Although this shows the internal coolant does transfer heat more efficiently than the external method, the following important points should be considered. (1) The cutting insert is monolithic Al 2 O 3 , as noted, water-based lubricants can impact wear rates, potentially resulting in dissolution of the Al 2 O 3 microstructure under contact points [ 9 ]. Therefore, ceramic materials may not perform optimally when external coolants are applied.…”

Section: Discussionmentioning

confidence: 99%

“…Cooling, either by external or internal approaches, helps reduce tool wear and improve thermal degradation, which affects the surface integrity of workpieces [6,7]. Currently, internal cooling within the tool structure is gaining interest as an alternative to conventional thermal flooding methods, which are expensive, potentially hazardous, and harmful to the environment [8][9][10].…”

Section: Need For Heat Reduction In Mechanical Cutting Processesmentioning

confidence: 99%

“…Therefore, a gradual reduction in heat rather than rapid quenching is required to avoid fractures induced by thermal shock, which is produced in the case of external flooding. Internal cooling can successfully remove the heat generated at the cutting tip, thereby extending the tool life and improving surface finish [6][7][8][9]. Generally, liquid water is used as a coolant and driven cyclically around the internal channel within the insert by means of a mechanical…”

Section: Requirements and Applicationmentioning

confidence: 99%

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Magnetohydrodynamic-based Internal Cooling System for a Ceramic Cutting Tool: Concept Design, Numerical Study, and Experimental Validation

O’Hara,

Fang

2023

Nanomanuf Metrol

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The effective removal of the heat generated during mechanical cutting processes is crucial to enhancing tool life and producing workpieces with superior surface finish. The internal cooling systems used in cutting inserts employ a liquid water-based solvent as the primary medium to transport the excess thermal energy generated during the cutting process. The limitations of this approach are the low thermal conductivity of water and the need for a mechanical input to circulate the coolant around the inner chamber of the cutting tool. In this context, this paper proposes an alternative method in which liquid gallium is used as the coolant in combination with a magnetohydrodynamic (MHD) pump, which avoids the need for an external power source. Using computational fluid dynamics, we created a numerical model of an internal cooling system and then solved it under conditions in which a magnetic field was applied to the liquid metal. This was followed by a simulation study performed to evaluate the effectiveness of liquid gallium over liquid water. The results of experiments conducted under non-cooling and liquid gallium cooling conditions were analyzed and compared in terms of the tool wear rate. The results showed that after six machining cycles at a cutting speed Vc = 250 m min −1, the corner wear VBc rate was 75 µm with the coolant off and 48 µm with the MHD-based coolant on, representing a decrease of 36% in tool wear. At Vc = 900 m min−1, the corner wear VBc rate was 75 µm with the coolant off and 246 µm with the MHD-based coolant on, representing a decrease of 31% in tool wear. When external cooling using liquid water was added, the results showed at Vc = 250 m min−1, the difference between the tool wear rate reduction with the internal liquid gallium coolant relative to the external coolant was 29%. When the cutting speed was increased to Vc = 900 m min−1, the difference observed between the internal liquid gallium coolant relative to the external coolant was 16%. The study proves the feasibility of using liquid gallium as a coolant to effectively remove thermal energy through internally fabricated cooling channels in cutting inserts.

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Section: Discussionmentioning

confidence: 99%

Section: Need For Heat Reduction In Mechanical Cutting Processesmentioning

confidence: 99%

Section: Requirements and Applicationmentioning

confidence: 99%

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Magnetohydrodynamic-based Internal Cooling System for a Ceramic Cutting Tool: Concept Design, Numerical Study, and Experimental Validation

O’Hara,

Fang

2023

Nanomanuf Metrol

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“…In the turning process, the high temperatures created during material removal can result in the thermal ablation of the tool cutting edge, thus increasing the rate of tool wear which invariably impacts the quality of the machined surface and dimensional accuracy. The most common way to address the control of the high temperatures experienced during mechanical cutting has been with the use of external water-based coolants [ 2 – 4 ]. However, there is general recognition that the wide use of these substances has a detrimental effect on the environment once removed as waste disposal [ 5 , 6 ].…”

Section: Introductionmentioning

confidence: 99%

“…Utilizing a relatively complex design, Öztürk et al [ 4 ] used an in/out liquid water coolant flow that dispersed onto the base of the insert. Then combining with a coolant reservoir, aluminium blocks were used in conjunction with integrated Peltier modules operating as a fan to transfer heat.…”

Section: Introductionmentioning

confidence: 99%

Study on magnetohydrodynamic internal cooling mechanism within an aluminium oxide cutting tool

O’Hara,

Fang

2024

Int J Adv Manuf Technol

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One of the challenges in the transfer of heat during the mechanical machining process is the coolant substance used in the internal cooling method which is generally liquid water or a water-based coolant. This limits the heat transfer capacity insofar as the thermal conductivity of liquid water is concerned. The other difficulty is the requirement for an external mechanical system to pump the coolant around the internal channel, providing efficient transfer of the accumulated thermal energy. This study proposes a novel method to address this issue by using liquid gallium which provides the means to transfer the excess heat generated during the cutting process by integrating the design into an aluminium oxide insert. Combining this with a magnetohydrodynamic drive, the coolant system operates without the need for mechanical input. Liquid gallium is nontoxic and has a much higher thermal conductivity over liquid water. Investigations of the novel cooling system is performance compared against liquid water through numerical modelling, followed by an experimental machining test to ascertain the difference in heat transfer effectiveness, tool wear rates and workpiece surface finish when compared to dry machining and external cooling conditions on stainless steel 316L. Without cooling, experimental machining tests employing a cutting speed of Vc = 250 m min−1 resulted in a corner wear VBc rate of 75 μm, and with the magnetohydrodynamic-based coolant on, produced a VBc rate of 48 μm, indicating a difference of 36% in relative tool wear under the same cutting conditions. Increasing the cutting speed Vc to 900 m min−1, produced a corner wear VBc rate of 357 μm without the active coolant and a VBc rate of 246 μm with the magnetohydrodynamic-based coolant on, representing a decrease of 31% in relative tool wear. Further tests comparing external liquid water cooling against the liquid gallium coolant showed at Vc = 250 m min−1, a difference of 29% in relative tool wear rate reduction was obtained with the internal liquid gallium coolant. Increasing the cutting speed to Vc = 900 m min−1, the data indicated a difference of 16% relative tool wear reduction with the internal liquid gallium. The results support the feasibility of using liquid gallium as an internal coolant in cutting inserts to effectively remove thermal energy.

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Cutting temperature measurement and prediction in machining processes: comprehensive review and future perspectives

Guimarães

Fernandes²,

Figueiredo³

et al. 2022

Int J Adv Manuf Technol

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Investigation on an Innovative Internally Cooled Smart Cutting Tool with the Built-in Cooling-Control System

Cited by 17 publications

References 28 publications

Magnetohydrodynamic-based Internal Cooling System for a Ceramic Cutting Tool: Concept Design, Numerical Study, and Experimental Validation

Magnetohydrodynamic-based Internal Cooling System for a Ceramic Cutting Tool: Concept Design, Numerical Study, and Experimental Validation

Study on magnetohydrodynamic internal cooling mechanism within an aluminium oxide cutting tool

Cutting temperature measurement and prediction in machining processes: comprehensive review and future perspectives

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