Research Papers

An Innovative Method to Measure the Cutting Temperature in Process by Using an Internally Cooled Smart Cutting Tool

[+] Author and Article Information
Shengrong Shu

School of Mechatronics Engineering,
Harbin Institute of Technology,
P.O. Box 413,
Harbin 150001, China
e-mail: shushengrong201@163.com

Kai Cheng

School of Mechatronics Engineering,
Harbin Institute of Technology,
P.O. Box 413,
Harbin 150001, China;
School of Engineering and Design,
Brunel University,
Middlesex UB8 3PH, UK
e-mail: kai.cheng@brunel.ac.uk

Hui Ding

e-mail: dhalbert@hit.edu.cn

Shijin Chen

e-mail: sjchen@hit.edu.cn
School of Mechatronics Engineering,
Harbin Institute of Technology,
P.O. Box 413,
Harbin 150001, China

1Corresponding author.

Manuscript received May 1, 2013; final manuscript received October 14, 2013; published online November 18, 2013. Assoc. Editor: Yung Shin.

J. Manuf. Sci. Eng 135(6), 061018 (Nov 18, 2013) (11 pages) Paper No: MANU-13-1204; doi: 10.1115/1.4025742 History: Received May 01, 2013; Revised October 14, 2013

This paper presents a novel approach to measure the cutting temperature in process and control it to some extent by using an internally cooled smart cutting tool with a closed internal cooling circuitry. Numerical modeling based on the finite element analysis-computational fluid dynamics (CFD) method is carried out by using ansys and fluent, then the surface temperature distribution of the tool is fitted and the equivalent heat transfer coefficient of the tool surface contacting with cooling fluid is computed. Analytical thermal model of the tool is established based on the lumped parameter method. Theoretical analysis and numerical simulation results are in good agreement, which demonstrate that the innovative smart tooling design concept can effectively sense the cutting temperature at the cutting tool tip in process and also be used to reduce and control the critical cutting temperature in cutting zone for adaptive machining of difficult-to-machine materials, such as titanium and Inconel alloys. Experimental cutting trials are carried out to further examine and validate the method and concept of applying the smart cutting tool system.

Copyright © 2013 by ASME
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Fig. 1

Schematic view of the smart cutting tool

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Fig. 2

Conceptual illustration of the cutting temperature measurement and internally cooled tooling structure: (a) cutting temperature computed by using cooling inlet and outlet temperatures and (b) cooling fluid flowing routes and geometrically travelling distances within the smart cutting tool

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Fig. 3

Schematic view of the tooling insert and the definition of coordinate systems: (a) the definition of the surfaces of carbide insert and (b) the definition of coordinate systems

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Fig. 4

Modeling and simulation illustration of the tool temperature contours and fluid velocity: (a) tool temperature contours with internal cooling, (b) velocity of the cooling fluid, and (c) temperature distribution on the noncooled tool

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Fig. 5

Temperature along the line L1, L2, L3 at t = 10 s

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Fig. 6

Temperature along the line L1 at different moments

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Fig. 7

Thermal resistance network on the tool

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Fig. 12

Offline experiment setup of the internally cooled tool

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Fig. 11

Relationship between average cutting temperature and temperature difference at various contact areas

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Fig. 10

Influence of the inlet velocity on the cutting temperature reduction and the outlet temperature

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Fig. 9

Comparison of outlet temperature

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Fig. 8

Comparison of the average cutting temperature

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Fig. 13

Experimental relationship between the average interface temperature and temperature difference

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Fig. 14

Experimental setup for cutting tests

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Fig. 15

Rake faces of a cutting tool before and after a cutting test: (a) rake face before cutting and (b) rake face after a cutting test

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Fig. 16

The sampling of infrared images obtained in cutting process with a cutting speed of 670 rpm: (a) infrared images without cooling and (b) infrared images with internal cooling

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Fig. 17

Comparison of analytical, numerical, and experimental results for two cutting conditions: (a) comparison of average cutting temperature and (b) comparison of outlet temperature



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