Investigation on an Innovative Internally Cooled Smart Cutting Tool with the Built-in Cooling-Control System

摘要

There is a growing demand for sustainable and health-friendly chip removal applications in manufacturing industries. Internallycooled cutting tool (ICCT) designs promise low cost, eco-friendly cooling and no hazardous health effects. However, theICCTs neither can estimate insert tip temperature (T_(tip)) precisely nor fix T_(tip) in determined temperature range by operatorwith 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 manufacturedfor the turning operations. In this framework, a cutting tool has been modified with a new self-designed seat which has aninclined gap to spray the cutting fluid below the insert tip. Then, an innovative cooling-control system has been integratedto the cutting tool. An original and developable computational fluid dynamics (CFD)-statistic calibration method has beenrevealed to estimate Ttip. According to the calibration method enhanced with coding self-working strategy, the ICSCT cancalculate T_(tip) by measuring the flank surface temperature (T_f), inlet temperature (Tinlet) and inlet velocity (v_f). In conclusion,the ICSCT could decrease Ttip by up to 107 °C compared to no cooling in experiments. Whilst v_f went up, T_f showed adecreasing trend. Whilst T_(inlet) went up, T_f values increased. Moreover, 1040 steel workpieces were machined and the averagesurface roughness from turning with the ICSCT was measured significantly less than dry turning under the same cuttingparameters.