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.

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