Magnetohydrodynamic-based Internal Cooling System for a Ceramic Cutting Tool: Concept Design, Numerical Study, and Experimental Validation
John O’Hara,
Fengzhou Fang
Abstract:The effective removal of the heat generated during mechanical cutting processes is crucial to enhancing tool life and producing workpieces with superior surface finish. The internal cooling systems used in cutting inserts employ a liquid water-based solvent as the primary medium to transport the excess thermal energy generated during the cutting process. The limitations of this approach are the low thermal conductivity of water and the need for a mechanical input to circulate the coolant around the inner chamb… Show more
“…18 Corner wear VB c rates under conditions of dry and internal cooling ( a ) Number of machining cycles for the cutting insert at V c = 250 m min −1 , and ( b ) at V c = 900 m main − . 1 [ 20 ] Fig. 19 Tool wear reduction.…”
Section: Resultsmentioning
confidence: 99%
“…( a ) MHD cooling system vs no cooling. ( b ) MHD cooling system vs external cooling with liquid water [ 20 ] …”
Section: Resultsmentioning
confidence: 99%
“…This paper develops a numerical model which aims to investigate the potential of an internal magnetohydrodynamic system as an alternative to external coolants when machining 316L. This is developed using an Al 2 O 3 insert with a geometrically defined internal cooling channel [ 20 ]. A detailed simulation model is created which focuses on thermal transfer during machining and uses a two-step approach in developing the heat transfer mechanism through the decomposition of the cutting tool interface problem.…”
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.
“…18 Corner wear VB c rates under conditions of dry and internal cooling ( a ) Number of machining cycles for the cutting insert at V c = 250 m min −1 , and ( b ) at V c = 900 m main − . 1 [ 20 ] Fig. 19 Tool wear reduction.…”
Section: Resultsmentioning
confidence: 99%
“…( a ) MHD cooling system vs no cooling. ( b ) MHD cooling system vs external cooling with liquid water [ 20 ] …”
Section: Resultsmentioning
confidence: 99%
“…This paper develops a numerical model which aims to investigate the potential of an internal magnetohydrodynamic system as an alternative to external coolants when machining 316L. This is developed using an Al 2 O 3 insert with a geometrically defined internal cooling channel [ 20 ]. A detailed simulation model is created which focuses on thermal transfer during machining and uses a two-step approach in developing the heat transfer mechanism through the decomposition of the cutting tool interface problem.…”
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.
Electron beam lithography (EBL) involves the transfer of a pattern onto the surface of a substrate by first scanning a thin layer of organic film (called resist) on the surface by a tightly focused and precisely controlled electron beam (exposure) and then selectively removing the exposed or nonexposed regions of the resist in a solvent (developing). It is widely used for fabrication of integrated circuits, mask manufacturing, photoelectric device processing, and other fields. The key to drawing circular patterns by EBL is the graphics production and control. In an EBL system, an embedded processor calculates and generates the trajectory coordinates for movement of the electron beam, and outputs the corresponding voltage signal through a digital-to-analog converter (DAC) to control a deflector that changes the position of the electron beam. Through this procedure, it is possible to guarantee the accuracy and real-time control of electron beam scanning deflection. Existing EBL systems mostly use the method of polygonal approximation to expose circles. A circle is divided into several polygons, and the smaller the segmentation, the higher is the precision of the splicing circle. However, owing to the need to generate and scan each polygon separately, an increase in the number of segments will lead to a decrease in the overall lithography speed. In this paper, based on Bresenham’s circle algorithm and exploiting the capabilities of a field-programmable gate array and DAC, an improved real-time circle-producing algorithm is designed for EBL. The algorithm can directly generate circular graphics coordinates such as those for a single circle, solid circle, solid ring, or concentric ring, and is able to effectively realizes deflection and scanning of the electron beam for circular graphics lithography. Compared with the polygonal approximation method, the improved algorithm exhibits improved precision and speed. At the same time, the point generation strategy is optimized to solve the blank pixel and pseudo-pixel problems that arise with Bresenham’s circle algorithm. A complete electron beam deflection system is established to carry out lithography experiments, the results of which show that the error between the exposure results and the preset patterns is at the nanometer level, indicating that the improved algorithm meets the requirements for real-time control and high precision of EBL.
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