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Research Papers

A Coupling Approach Combining Computational Fluid Dynamics and Finite Element Method to Predict Cutting Fluid Effects on the Tool Temperature in Cutting Processes

[+] Author and Article Information
Thorsten Helmig

Institute of Heat and Mass Transfer (WSA),
RWTH Aachen University,
52074 Aachen, Germany
e-mail: helmig@wsa.rwth-aachen.de

Bingxiao Peng

Laboratory for Machine Tools and Production Engineering (WZL),
RWTH Aachen University,
52062 Aachen, Germany
e-mail: b.peng@wzl.rwth-aachen.de

Claas Ehrenpreis

Institute of Heat and Mass Transfer (WSA),
RWTH Aachen University,
52074 Aachen, Germany
e-mail: ehrenpreis@wsa.rwth-aachen.de

Thorsten Augspurger

Laboratory for Machine Tools and Production Engineering (WZL),
RWTH Aachen University,
52062 Aachen, Germany
e-mail: t.augspurger@wzl.rwth-aachen.de

Yona Frekers

Institute of Heat and Mass Transfer (WSA),
RWTH Aachen University,
52074 Aachen, Germany
e-mail: frekers@wsa.rwth-aachen.de

Reinhold Kneer

Institute of Heat and Mass Transfer (WSA),
RWTH Aachen University,
52074 Aachen, Germany
e-mail: kneer@wsa.rwth-aachen.de

Thomas Bergs

Laboratory for Machine Tools and Production Engineering (WZL),
RWTH Aachen University,
52062 Aachen, Germany
e-mail: t.bergs@wzl.rwth-aachen.de

1Corresponding author.

Manuscript received May 7, 2018: final manuscript received May 23, 2019; published online July 31, 2019. Editor: Y. Lawrence Yao.

J. Manuf. Sci. Eng 141(10), (Jul 31, 2019) (6 pages) Paper No: MANU-19-1271; doi: 10.1115/1.4044102 History: Received May 07, 2019; Accepted May 23, 2019

In metal cutting processes, the use of cutting fluids shows significant effects on workpiece surface quality by reducing thermomechanical loads on cutting tool and workpiece. Many efforts are made to model these thermomechanical processes, however without considering detailed heat transfer between cutting fluid, tool, and workpiece. To account for heat transfer effects, a coupling approach is developed, which combines computational fluid dynamics (CFD) and finite element method (FEM) chip formation simulation. Prior to the simulation, experimental investigations in orthogonal cutting in dry and wet cutting conditions with two different workpiece materials (AISI 1045 and DA 718) are conducted. To measure the tool temperature in dry as well as in wet cutting conditions, a two color pyrometer is placed inside an electrical discharge machining (EDM) drilled cutting tool hole. Besides tool temperature, the cutting force is recorded during the experiments and later used to calculate heat source terms for the CFD simulation. After the experiments, FEM chip formation simulations are performed and provide the chip forms for the CFD mesh generation. In general, CFD simulation and experiment are in reasonable agreement, as for each workpiece setup the measured temperature data are located between the simulation results from the two different tool geometries. Furthermore, numerical and experimental results both show a decrease of tool temperature in wet cutting conditions, however revealing a more significant cooling effect in a AISI 1045 workpiece setup. The results suggest that the placement of drilling holes has a major influence on the local tool temperature distribution, as the drilling hole equals a thermal resistance and hence leads to elevated temperatures at the tool front.

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References

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Figures

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Fig. 1

Procedure of the developed approach

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Fig. 2

Experimental setup on the broaching machine

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Fig. 3

Cutting forces in dry and wet conditions

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Fig. 4

Concept of the CEL-based FE model

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Fig. 5

Chip form from the FEM chip formation simulations

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Fig. 6

Illustration of the numerical setup and boundary conditions used for CFD simulations

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Fig. 7

Close-up of the tool in the computational domain with and without the EDM drilling hole for the pyrometer measurements. The arrows illustrate qualitatively the directions of heat flux for different setups investigated.

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Fig. 8

Contour plots obtained from CFD simulation. Solid tool temperature under (a) wet conditions, (b) volume fraction of cooling lubricant, and (c) fluid phase velocity of a AISI 1045 workpiece setup.

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Fig. 9

Tool temperature evolution of a AISI 1045 workpiece setup under dry and wet conditions, obtained from experiments (Exp.) and CFD simulations (Sim.)

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Fig. 10

Tool temperature evolution of a DA 718 workpiece setup under dry and wet conditions, obtained from experiments (Exp.) and CFD simulations (Sim.)

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Fig. 11

Influence of heat flux partitioning on the tool temperature for a AISI 1045 workpiece setup (Results from CFD simulations). The total heat flux (the sum of chip and rakeface) is kept constant.

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