CFD simulation to optimize the internal coolant channels of an additively manufactured milling tool

Zachert, Christoph; Hui, Liu; Lakner, Thomas; Schraknepper, Daniel; Bergs, Thomas

doi:10.1016/j.procir.2021.09.040

Cited by 10 publications

(2 citation statements)

References 18 publications

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“…These form part of the boundary conditions, in which the heat is absorbed or transferred from the solid body across to the fluid or vice versa. The challenge in solving this problem through analytical methods is partly due to the transient nature of the process which is highly complex [ 30 , 40 ]. To circumvent this, a conjugation of the boundary condition at the solid–liquid phase through coupled heat transfer analysis is employed via a numerical method.…”

Section: Numerical Modellingmentioning

confidence: 99%

Study on magnetohydrodynamic internal cooling mechanism within an aluminium oxide cutting tool

O’Hara,

Fang

2024

Int J Adv Manuf Technol

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One of the challenges in the transfer of heat during the mechanical machining process is the coolant substance used in the internal cooling method which is generally liquid water or a water-based coolant. This limits the heat transfer capacity insofar as the thermal conductivity of liquid water is concerned. The other difficulty is the requirement for an external mechanical system to pump the coolant around the internal channel, providing efficient transfer of the accumulated thermal energy. This study proposes a novel method to address this issue by using liquid gallium which provides the means to transfer the excess heat generated during the cutting process by integrating the design into an aluminium oxide insert. Combining this with a magnetohydrodynamic drive, the coolant system operates without the need for mechanical input. Liquid gallium is nontoxic and has a much higher thermal conductivity over liquid water. Investigations of the novel cooling system is performance compared against liquid water through numerical modelling, followed by an experimental machining test to ascertain the difference in heat transfer effectiveness, tool wear rates and workpiece surface finish when compared to dry machining and external cooling conditions on stainless steel 316L. Without cooling, experimental machining tests employing a cutting speed of Vc = 250 m min−1 resulted in a corner wear VBc rate of 75 μm, and with the magnetohydrodynamic-based coolant on, produced a VBc rate of 48 μm, indicating a difference of 36% in relative tool wear under the same cutting conditions. Increasing the cutting speed Vc to 900 m min−1, produced a corner wear VBc rate of 357 μm without the active coolant and a VBc rate of 246 μm with the magnetohydrodynamic-based coolant on, representing a decrease of 31% in relative tool wear. Further tests comparing external liquid water cooling against the liquid gallium coolant showed at Vc = 250 m min−1, a difference of 29% in relative tool wear rate reduction was obtained with the internal liquid gallium coolant. Increasing the cutting speed to Vc = 900 m min−1, the data indicated a difference of 16% relative tool wear reduction with the internal liquid gallium. The results support the feasibility of using liquid gallium as an internal coolant in cutting inserts to effectively remove thermal energy.

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Section: Numerical Modellingmentioning

confidence: 99%

Study on magnetohydrodynamic internal cooling mechanism within an aluminium oxide cutting tool

O’Hara,

Fang

2024

Int J Adv Manuf Technol

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“…The AM tool's focused cutting-fluid channels on the rake face resulted in reduced tool wear, cutting forces, and vibrations. They also experimented with optimising the shape of the nozzle through CFD analysis [4]. New nozzle designs with different channel designs (sharp edge, curved, and helical) and angles (0°and 30°) are tested on milling cutters.…”

Section: Introductionmentioning

confidence: 99%

Characterization of 3D metal printed cutting tool with transpiration cooling channels

S S,

Muralidharan

2023

Mater. Res. Express

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This study characterizes the 3D printed transpiration cooling (TC) channels in a single-point cutting tool to enhance the lubrication and cooling at the cutting zones. Five different TC channels namely two circular profiled channels (Design 1-A & 1-B), one hexagonal (Designs 2-A & 2-B) profiled channels, one bio-inspired blood vessel (Designs 3) are designed inside a single-point turning tool and 3D printed using AISI-1.2709 in powder bed fusion (PBF). From the materials and mechanical characterisation, fine cellular microstructure and high hardness is achieved. X-ray micro computed tomography (XRµCT) has been used as a non-destructive inspection strategy to analyse the built structures. The results of XRµCT showed that the TC channel built is highly orientation dependant, steeper angles deviates highly and nominal angles such as 0º and 90º (to the build platform) provides the best dimensional accuracy. The average dimensional deviations of the five designs are -35.8%, -19.42%, -19.45%, -15.85%, and -5.02%, respectively from the as-designed. The best designs are circular free-form (Design 1-B), hexagonal free-form (Design 2-B) and bio-inspired blood vessel (Design 3), which has the least dimensional deviation and highest accuracy.

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Optimal design of gyroid solid-TPMS structures for 8-inch wafer prober lower chuck in additive manufacturing

Kim,

Park,

Lee

et al. 2024

J Mech Sci Technol

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CFD simulation to optimize the internal coolant channels of an additively manufactured milling tool

Cited by 10 publications

References 18 publications

Study on magnetohydrodynamic internal cooling mechanism within an aluminium oxide cutting tool

Study on magnetohydrodynamic internal cooling mechanism within an aluminium oxide cutting tool

Characterization of 3D metal printed cutting tool with transpiration cooling channels

Optimal design of gyroid solid-TPMS structures for 8-inch wafer prober lower chuck in additive manufacturing

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