Design of an internally cooled turning tool based on topology optimization and CFD simulation

Abstract

Cutting fluid is traditionally used to remove the generated heat during the metal cutting process. Employing cutting fluid outside the cutting tools may result in environmental pollution, health hazards, and other significant negative consequences. Internally cooled cutting tools are thus desirable and promising for the machining industry. In this paper, an internally cooled turning tool is designed based on topology optimization and CFD simulation, followed by solid isotropic material with penalization (SIMP) model imported in mechanical and heat conduction analyzing models for the tool flow channel design and optimization. The mechanical and thermal results are utilized on a traditional tool to formulate a sound topology optimization model of the internally cooled tool. In comparison with the performance of the traditional tool, the newly designed one can greatly reduce the heat as well as the maximum temperature with minimum deformation. Key performance of the newly configured tool, including thermal field distribution, best flow speed, maximum cooling capacity and maximum tool temperature, are simulated under different flow speeds by fluid-structure interaction thermal analysis.