Abstract
Supplying coolant through internal coolant channels is a common method of transporting large thermal loads away from the tool in twist-drill machining to increase tool life, aid chip evacuation and avoid catastrophic tool failure. In this work a finite element-based numerical model of the machining process is loosely coupled with a finite volumebased numerical method for predicting the distribution of coolant inside the borehole. These methods are employed to study the effect of channel position on cutting geometry lubrication and uses response surface models to show that all designs do not fully flood the borehole and that not all areas of the tool geometry are lubricated with coolant. Visual analysis of results show that coolant, for all designs, primarily lubricates the area between the cutting edge and the coolant hole exit, however depending on application requirements coolant channel positioning can be used to modify coolant supply to the axial rake, for chip evacuation or to the cutting edge for heat removal.
Highlights
Twist-drill machining is a process of creating cylindrical holes frequently used in the manufacture of cars, trains, planes and ships and are typically comprised of two components, the drill and the cutting tool [1]
The profile of coolant calculated by the Computational Fluid Dynamics (CFD) model is clearly in qualitative agreement with the profile shown in the experiment
Response Surface Modelling The effect of coolant channel exit circumferential positioning, θ, and radial positioning, r, on tool wetting and borehole flooding is shown through response surfaces
Summary
Twist-drill machining is a process of creating cylindrical holes frequently used in the manufacture of cars, trains, planes and ships and are typically comprised of two components, the drill and the cutting tool (referred to as the drill bit) [1]. In twist-drill machining, research by Obikawa et al [9] studied coolant flow between the tool flank face and the workpiece surface in response to changes in flow rate. Özkaya et al [5] employed a single-phase model to study the effects of coolant hole position and flow rate on tool-coolant heat transfer in Inconel 718 drilling.
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