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Prediction of the convective heat transfer coefficient of cutting fluid in helical drills

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Journal of the Brazilian Society of Mechanical Sciences and Engineering Aims and scope Submit manuscript

Abstract

Environmental, economical and social factors impose the elimination or reduction of the quantity of the cutting fluids used in the machining. This trend leads to a high temperature in the cutting zone. In drilling, when the cutting fluid is not supplied through the spindle, the tool tip suffers from high temperature, leading to rapid wear. In this case, the cooling of the drill tool body can contribute significantly removing the heat generated at the tool–chip interface. However, to effectively simulate the temperature at the tool tip, the effect of the cutting fluid on tool body must be known. Hence, the aim of this work was to determine the convective heat transfer coefficient of the cutting fluid on the complex body of a helical drill. In this regard, a special experimental setup is developed, allowing the drill to remain static while the coolant nozzle rotates around providing cutting fluid. A method is developed in order to determine the temperature on the drill surface as a function of the heat enters into the drill and the temperature measured at the tool base. Experiments are carried out varying coolant nozzle rotation speed and the cutting fluid flow rate. According to the results, the cutting fluid flow rate shows to have the most significant effect on the convective heat transfer coefficient.

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Abbreviations

\(\nabla\) :

Laplace operator vector

\(A_2\) :

Contact area of the drill with the cutting fluid (m\(^2\))

\(A_\mathrm{b}\) :

Surface back area of the heating system (m\(^2\))

\(A_\mathrm{f}\) :

front surface area of the heating system (m\(^2\))

\(A_{1,3}\) :

Cross-sectional area of the drill (m\(^2\))

\(E_\mathrm{f,t,l}\) :

Insulation thickness (m)

h :

Convective heat transfer coefficient (W/m\(^2\) K)

I :

Current (A)

k :

Thermal conductivity of the tool material (W/mK)

\(k_\mathrm{i}\) :

Thermal conductivity of the insulation (W/mK)

L :

Insulation length (m)

\(l_\mathrm{f}\) :

Cutting fluid flow rate (l/h)

\(Q_\mathrm{d}\) :

Heat entering the drill (W)

\(Q_\mathrm{f}\) :

Heat removed by the cutting fluid (W)

\(Q_\mathrm{r}\) :

Heat supplied by the electric resistance (W)

\(Q_{l1 \ldots l3}\) :

Heat lost at the heating system (W)

\(R_\mathrm{n}\) :

Nozzle rotating speed (rpm)

\(R_{1 \ldots 4}\) :

Regions of the drill (rpm)

\(r_\mathrm{e,i}\) :

Insulation radius (m)

\(S_{1,2,3}\) :

Surfaces of the drill (m\(^2\))

T :

Temperature in the drill (\(^{\circ }\)C)

\(T_{1} \,\ldots\, T_{5}\) :

Temperatures inside the heating system (\(^{\circ }\)C)

\(T_\mathrm{a}\) :

Room temperature (\(^{\circ }\)C)

\(T_\mathrm{d}\) :

Temperature on the drill surface (\(^{\circ }\)C)

\(T_\mathrm{f}\) :

Cutting fluid temperature (\(^{\circ }\)C)

\(T_\mathrm{b1}\) :

Temperature on the surface \(A_3\) (\(^{\circ }\)C)

\(T_\mathrm{b2}\) :

Temperature on the back of the tool (\(^{\circ }\)C)

U :

Voltage (V)

\(\mathrm{VC}_1,2\) :

Control volume

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Authors and Affiliations

  1. Department of Mechanical Engineering, Santa Catarina State University, Campus Universitario, Joinville, 89219-710, Brazil

    Douglas Wellington Pontes, Joel Martins Crichigno Filho & Paulo Sérgio Berving Zdanski

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  1. Douglas Wellington Pontes
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  2. Joel Martins Crichigno Filho
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  3. Paulo Sérgio Berving Zdanski
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Correspondence to Joel Martins Crichigno Filho.

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Technical Editor: Márcio Bacci da Silva.

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Pontes, D.W., Crichigno Filho, J.M. & Zdanski, P.S.B. Prediction of the convective heat transfer coefficient of cutting fluid in helical drills. J Braz. Soc. Mech. Sci. Eng. 39, 5195–5204 (2017). https://doi.org/10.1007/s40430-017-0904-8

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  • DOI: https://doi.org/10.1007/s40430-017-0904-8

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