An independent internal cooling system for promoting heat dissipation during dry cutting with numerical and experimental verification

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.