Design of a novel turning tool cooled by combining circulating internal cooling with spray cooling for green cutting

Abstract

Cooling technology is vital in manufacturing industry, which can decrease cutting temperature, assist chip removal and reduce or eliminate the generation of cutting liquid waste during metal cutting process. This paper presents a novel turning tool cooled by combining circulating internal cooling with spray cooling, which can cool the cutting tool tip from inside and outside of insert and assist blow chips away from cutting zone. Thermal-fluid-solid coupling analysis using ANSYS Fluent is employed to investigate cooling performance of the composite cooling turning tool. Optimization of the internal spray cooling structure is carried out by Taguchi Method based CFD simulations and the optimal geometric parameters are picked out. The prototype of the novel turning tool is fabricated through the integration of spray cooling technology into the previously developed circulating internal cooling turning tool. The cooling effectiveness and practicality of the proposed novel turning tool system are further examined and validated by cutting trials.

Keywords

• spray cooling
• circulating internal cooling
• cfd simulation
• taguchi method
• green machining