Abstract
The cooling system has emerged as an effective way to alleviate the excessive heat generation during dry cutting processes. In this paper, we investigated a novel type of internal cooling system, independent of additional mechanical accessories, as a promising cooling alternative. The proposed system is devised as connected internal fluid channels of a-“V” shape created according to the geometric shape of the tool-holder. Enabling quantitative evaluation of the effectiveness of the proposed system, a new numerical approach is established. Within the approach, heat transfer equations are deduced according to thermodynamics; parameters of the equations are specified via analytical modeling. As a result, cutting temperatures can be estimated with high precision according to the outlet temperature. Moreover, a cutting experiment was carried out to verify the effectiveness of the proposed numerical approach. Tool-chip interface temperatures were measured using an infrared thermal imager. Smooth measurements with suppressed noises are derived based on a new adaptive mean filter originated by empirical mode decomposition (EMD). The experimental results demonstrate the proposed system can reduce the temperature substantially (almost 30% at the measuring point) and the results are highly consistent with those of numerical simulation. The proposed cooling system is a prospective enhancement for development of smart cutting tools.
Highlights
An excessiverise in temperature due to heat generation during the cutting process is an important issue that accelerates tool wear and affects machining accuracy and surface quality of the finished workpieces [1]
Dry machining can be considered as a feasible approach to eliminate the use of cutting fluids because of low processing cost and soft ecological hazard [4]
Tool–chip pressure, high temperature, and intense friction applied to the tool-chip interface during the pressure, high temperature, and intense friction applied to the tool-chip interface during the machining machining process
Summary
An excessiverise in temperature due to heat generation during the cutting process is an important issue that accelerates tool wear and affects machining accuracy and surface quality of the finished workpieces [1]. Minton created a modified tool-holder with an internally cooled tool to enhance the heat transfer [12] In these two studies, pyrometers were employed to monitor the rise of cutting temperature and evaluate the enhancement of cooling effect. Among the above reported literature, research on ICS mainly focuses on modifications of tool-holder forms, support seat or the insert These methods above can be improved, they usually require additional supply devices that inevitably increase the complexity of the machining tool or modify the machine tool structure, significantly limiting industrial applications. Considering the pros and cons of the above cooling methods, in this paper, a novel independent cooling system based on an internal cooling fluid channel is devised and applied to promote heat dissipation during cutting process. The experimental results demonstrated the effectiveness of the novel independent ICS and the improved cooling performance
Sign-in/Register to view highlights & summary Sign-in/Register to access full text options 
Talk to us
Join us for a 30 min session where you can share your feedback and ask us any queries you have
Schedule a callDisclaimer: All third-party content on this website/platform is and will remain the property of their respective owners and is provided on "as is" basis without any warranties, express or implied. Use of third-party content does not indicate any affiliation, sponsorship with or endorsement by them. Any references to third-party content is to identify the corresponding services and shall be considered fair use under The CopyrightLaw.
