Investigation on an Innovative Internally Cooled Smart Cutting Tool with the Built-in Cooling-Control System
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RESEARCH ARTICLE-MECHANICAL ENGINEERING
Investigation on an Innovative Internally Cooled Smart Cutting Tool with the Built-in Cooling-Control System 2 Erkan Öztürk1 · Kemal Yıldızlı1 · Fatih Saglam ˘
Received: 20 August 2020 / Accepted: 4 October 2020 © King Fahd University of Petroleum & Minerals 2020
Abstract There is a growing demand for sustainable and health-friendly chip removal applications in manufacturing industries. Internally cooled cutting tool (ICCT) designs promise low cost, eco-friendly cooling and no hazardous health effects. However, the ICCTs neither can estimate insert tip temperature (T tip ) precisely nor fix T tip in determined temperature range by operator with controlling cooling of the insert. Within this, the machining quality of metallic materials can improve. For this reason, a new internally cooled smart cutting tool built-in cooling-control system (ICSCT) has been designed and manufactured for the turning operations. In this framework, a cutting tool has been modified with a new self-designed seat which has an inclined gap to spray the cutting fluid below the insert tip. Then, an innovative cooling-control system has been integrated to the cutting tool. An original and developable computational fluid dynamics (CFD)-statistic calibration method has been revealed to estimate T tip . According to the calibration method enhanced with coding self-working strategy, the ICSCT can calculate T tip by measuring the flank surface temperature (T f ), inlet temperature (T inlet ) and inlet velocity (vf ). In conclusion, the ICSCT could decrease T tip by up to 107 °C compared to no cooling in experiments. Whilst vf went up, T f showed a decreasing trend. Whilst T inlet went up, T f values increased. Moreover, 1040 steel workpieces were machined and the average surface roughness from turning with the ICSCT was measured significantly less than dry turning under the same cutting parameters. Keywords Internal cooling · Smart tool · Cutting tool · Sustainable machining · Smart machining
Abbreviations CBN CFD CHT DC HCWI ICCT
B
Cubic boron nitride Computational fluid dynamics Conjugate heat transfer Direct current High chrome white cast iron Internally cooled cutting tool
Kemal Yıldızlı [email protected] Erkan Öztürk [email protected] Fatih Sa˘glam [email protected]
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2
Department of Mechanical Engineering, Faculty of Engineering, Ondokuz Mayıs University, 55200 Atakum, Samsun, Turkey Department of Statistics, Faculty of Art and Sciences, Ondokuz Mayıs University, 55200 Atakum, Samsun, Turkey
ICSCT LCD PID Ra T cr Td Tf T inlet T min T room T tip vf
Internally cooled smart cutting tool Liquid crystal display Proportional–integral–derivative Average surface roughness (µm) Maximum critical temperature (°C) Maximum dry-machining temperature (°C) Flank surface temperature (°C) Inlet temperature (°C) Minimum temperature (°C) Room/environment temperature (°C) Tip temperature of insert (°C) Fluid inlet velocity (m/s)
1 Introduction Thermal rises in cutting edges of the insert can lead
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