Skip to main content
SpringerLink
Log in

Ineffectiveness of flood cooling in reducing cutting temperatures during continuous machining

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Water-based metalworking fluids are applied in the form of a liquid jet to flood the entire cutting zone and increase the tool life. The objective of this study is to investigate the effectiveness of flood cooling in reducing the tool chip interface temperatures during continuous cutting. An instrumented smart cutting tool with a thin film temperature sensor was fabricated to accurately measure the real-time cutting temperatures from 1.3 µm below the tool chip interface in orthogonal turning of AISI 4140 steel under dry and flood cooling conditions. The cutting process was simulated in Deform 2D with the Johnson–Cook material model to present the transient temperature distributions on the coated cutting insert. The heat flux into the cutting tool was also estimated analytically and then three-dimensional finite element heat transfer simulations were performed to determine the maximum convective heat transfer of the cutting fluid in steady state. The measurements with the embedded thermocouple showed that flood cooling with a water-based cutting fluid slightly lowers the tool chip interface temperature. Moreover, the chip color may not be a good characteristic indicator to evaluate the cutting temperature in machining of metals. It was also found that flood cooling becomes more effective at a distance of approximately 150 µm from the cutting edge where the chip does not contact the rake face of the cutting tool.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9

Similar content being viewed by others

Availability of data and material

The data obtained in the framework of this study are available to the journal upon request.

Code availability

The codes are available to the journal upon request.

References

  1. Bennett EO (1983) Water based cutting fluids and human health. Tribol Int. https://doi.org/10.1016/0301-679X(83)90055-5

    Article  Google Scholar 

  2. Klocke F, Eisenblaetter G (1997) Dry cutting. CIRP Ann 46:519–526. https://doi.org/10.1016/S0007-8506(07)60877-4

    Article  Google Scholar 

  3. Seah KHW, Li X, Lee KS (1995) The effect of applying coolant on tool wear in metal machining. J Mater Process Tech. https://doi.org/10.1016/0924-0136(94)01688-W

    Article  Google Scholar 

  4. Ávila RF, Abrão AM (2001) The effect of cutting fluids on the machining of hardened AISI 4340 steel. J Mater Process Technol. https://doi.org/10.1016/S0924-0136(01)00891-3

    Article  Google Scholar 

  5. Jayal AD, Balaji AK (2009) Effects of cutting fluid application on tool wear in machining: Interactions with tool-coatings and tool surface features. Wear. https://doi.org/10.1016/j.wear.2009.06.032

    Article  Google Scholar 

  6. Khrais SK, Lin YJ (2007) Wear mechanisms and tool performance of TiAlN PVD coated inserts during machining of AISI 4140 steel. Wear. https://doi.org/10.1016/j.wear.2006.03.052

    Article  Google Scholar 

  7. Krolczyk GM, Nieslony P, Maruda RW, Wojciechowski S (2017) Dry cutting effect in turning of a duplex stainless steel as a key factor in clean production. J Clean Prod. https://doi.org/10.1016/j.jclepro.2016.10.136

    Article  Google Scholar 

  8. Revuru RS, Zhang JZ, Posinasetti NR (2020) Comparative performance studies of turning 4140 steel with TiC/TiCN/TiN-coated carbide inserts using MQL, flooding with vegetable cutting fluids, and dry machining. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-020-05378-8

    Article  Google Scholar 

  9. Paul S, Dhar NR, Chattopadhyay AB (2001) Beneficial effects of cryogenic cooling over dry and wet machining on tool wear and surface finish in turning AISI 1060 steel. J Mater Process Technol. https://doi.org/10.1016/S0924-0136(01)00839-1

    Article  Google Scholar 

  10. Ranjan Dhar N, Islam S, Kamruzzaman M (2007) Effect of minimum quantity lubrication (MQL) on tool wear, surface roughness and dimensional deviation in turning AISI-4340 steel

  11. Sivaiah P, Chakradhar D (2018) Effect of cryogenic coolant on turning performance characteristics during machining of 17–4 PH stainless steel: a comparison with MQL, wet, dry machining. CIRP J Manuf Sci Technol. https://doi.org/10.1016/j.cirpj.2018.02.004

    Article  Google Scholar 

  12. Leppert T (2011) Effect of cooling and lubrication conditions on surface topography and turning process of C45 steel. Int J Mach Tools Manuf. https://doi.org/10.1016/j.ijmachtools.2010.11.001

    Article  Google Scholar 

  13. Elbah M, Laouici H, Benlahmidi S et al (2019) Comparative assessment of machining environments (dry, wet and MQL) in hard turning of AISI 4140 steel with CC6050 tools. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-019-04403-9

    Article  Google Scholar 

  14. Ji X, Li B, Zhang X, Liang SY (2014) The effects of minimum quantity lubrication (MQL) on machining force, temperature, and residual stress. Int J Precis Eng Manuf. https://doi.org/10.1007/s12541-014-0612-6

    Article  Google Scholar 

  15. Rajaguru J, Arunachalam N (2020) A comprehensive investigation on the effect of flood and MQL coolant on the machinability and stress corrosion cracking of super duplex stainless steel. J Mater Process Technol. https://doi.org/10.1016/j.jmatprotec.2019.116417

    Article  Google Scholar 

  16. Sales WF, Diniz AE, Machado AR (2001) Application of cutting fluids machining processes. Rev Bras Ciencias Mec Brazilian Soc Mech Sci. https://doi.org/10.1590/S0100-73862001000200009

    Article  Google Scholar 

  17. Ezugwu EO, Bonney J, Yamane Y (2003) An overview of the machinability of aeroengine alloys. J Mater Process Technol. https://doi.org/10.1016/S0924-0136(02)01042-7

    Article  Google Scholar 

  18. Kurimoto T, Barrow G, Davies BJ (1982) The influence of aqueous fluids on the wear characteristics and life of carbide cutting tools. CIRP Ann - Manuf Technol. https://doi.org/10.1016/S0007-8506(07)63261-2

    Article  Google Scholar 

  19. Roy S, Ghosh A (2014) High-speed turning of AISI 4140 steel by multi-layered TiN top-coated insert with minimum quantity lubrication technology and assessment of near tool-tip temperature using infrared thermography. Proc Inst Mech Eng Part B J Eng Manuf. https://doi.org/10.1177/0954405413514570

    Article  Google Scholar 

  20. Hoyne AC, Nath C, Kapoor SG (2015) On cutting temperature measurement during titanium machining with an atomization-based cutting fluid spray system. J Manuf Sci Eng Trans ASME. https://doi.org/10.1115/1.4028898

    Article  Google Scholar 

  21. Klocke F, Krämer A, Sangermann H, Lung D (2012) Thermo-mechanical tool load during high performance cutting of hard-to-cut materials. In: Procedia CIRP

  22. Liu H, Meurer M, Schraknepper D, Bergs T (2022) Investigation of the cutting fluid’s flow and its thermomechanical effect on the cutting zone based on fluid–structure interaction (FSI) simulation. Int J Adv Manuf Technol 121:267–281. https://doi.org/10.1007/S00170-022-09266-1

    Article  Google Scholar 

  23. Kesriklioglu S, Arthur C, Morrow JD, Pfefferkorn FE (2019) Characterization of tool–chip interface temperature measurement with thermocouple fabricated directly on the rake face. J Manuf Sci Eng. https://doi.org/10.1115/1.4044035

    Article  Google Scholar 

  24. Stephenson DA (1993) Tool-work thermocouple temperature measurements—theory and implementation issues. J Manuf Sci Eng Trans ASME. https://doi.org/10.1115/1.2901786

    Article  Google Scholar 

  25. Dhar NR, Kamruzzaman M (2007) Cutting temperature, tool wear, surface roughness and dimensional deviation in turning AISI-4037 steel under cryogenic condition. Int J Mach Tools Manuf. https://doi.org/10.1016/j.ijmachtools.2006.09.018

    Article  Google Scholar 

  26. Khan MMA, Mithu MAH, Dhar NR (2009) Effects of minimum quantity lubrication on turning AISI 9310 alloy steel using vegetable oil-based cutting fluid. J Mater Process Technol. https://doi.org/10.1016/j.jmatprotec.2009.05.014

    Article  Google Scholar 

  27. Kesriklioglu S, Morrow JD, Pfefferkorn FE (2018) Tool-chip interface temperature measurement in interrupted and continuous oblique cutting. J Manuf Sci Eng Trans ASME. https://doi.org/10.1115/1.4038140

    Article  Google Scholar 

  28. Heigel JC, Ivester RW, Whitenton EP (2008) Cutting temperature measurements of segmented chips using dual-spectrum high-speed microvideography. In: Transactions of the North American Manufacturing Research Institution of SME

  29. Özel T (2006) The influence of friction models on finite element simulations of machining. Int J Mach Tools Manuf. https://doi.org/10.1016/j.ijmachtools.2005.07.001

    Article  Google Scholar 

  30. Johnson GR, Cook WH (1983) A constitutive model and data from metals subjected to large strains, high strain rates and high temperatures. In: Proc. 7th Int. Symp. on Ballistics, The Hague, Netherlands

  31. Pantalé O, Bacaria JL, Dalverny O et al (2004) 2D and 3D numerical models of metal cutting with damage effects. Comput Methods Appl Mech Eng. https://doi.org/10.1016/j.cma.2003.12.062

    Article  MATH  Google Scholar 

  32. Astakhov VP (2006) Tribology of metal cutting. Elsevier

    Google Scholar 

  33. Understanding cemented carbide. https://www.sandvik.coromant.com/en-us/knowledge/materials/pages/cutting-tool-materials.aspx. Accessed 8 Mar 2022

  34. Kesriklioglu S, Pfefferkorn FE (2019) Prediction of tool-chip interface temperature in cryogenic machining of ti-6al-4v: analytical modeling and sensitivity analysis. J Therm Sci Eng Appl. https://doi.org/10.1115/1.4040990

    Article  Google Scholar 

  35. Iqbal SA, Mativenga PT, Sheikh MA (2008) An investigative study of the interface heat transfer coefficient for finite element modelling of high-speed machining. Proc Inst Mech Eng Part B J Eng Manuf. https://doi.org/10.1243/09544054JEM1179

    Article  Google Scholar 

  36. Ning Y, Rahman M, Wong YS (2001) Investigation of chip formation in high speed end milling. In: J Mater Process Technol

  37. Su G, Xiao X, Du J et al (2020) On cutting temperatures in high and ultrahigh-speed machining. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-020-05054-x

    Article  Google Scholar 

  38. Chen SH, Luo ZR (2020) Study of using cutting chip color to the tool wear prediction. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-020-05354-2

    Article  Google Scholar 

  39. Li B, Zhang S, Wang R, Fang Y (2019) Toward understanding of metallurgical behaviours in dry machining of hardened steel: phase transformation and surface oxidation. J Mater Res Technol. https://doi.org/10.1016/j.jmrt.2019.06.042

    Article  Google Scholar 

  40. Loewen EG, Shaw MC (1954) On the analysis of cutting-tool temperatures. ASME Trans 76:217–225

    Google Scholar 

  41. Childs THC (2006) Friction modelling in metal cutting. Wear. https://doi.org/10.1016/j.wear.2005.01.052

    Article  Google Scholar 

  42. Platit. https://www.platit.com/media/filer/2020/compendium_en61.pdf. Accessed 21 Apr 2022

  43. Roy M (2017) Protective hard coatings for tribological applications. In: Materials under extreme conditions: recent trends and future prospects

  44. Rozzi JC, Sanders JK, Chen W (2011) The experimental and theoretical evaluation of an indirect cooling system for machining. J Heat Transfer. https://doi.org/10.1115/1.4002446

    Article  Google Scholar 

  45. Mann JB, Guo Y, Saldana C et al (2011) Modulation-assisted machining: a new paradigm in material removal processes. In: Adv Mat Res

  46. Karaguzel U, Budak E (2018) Investigating effects of milling conditions on cutting temperatures through analytical and experimental methods. J Mater Process Technol. https://doi.org/10.1016/j.jmatprotec.2018.07.024

    Article  Google Scholar 

  47. Gao Y, Mann JB, Chandrasekar S et al (2017) Modelling of tool temperature in modulation-assisted machining. In: Procedia CIRP

Download references

Acknowledgements

The author gratefully acknowledges Professor Frank E. Pfefferkorn and the Machine Tool Technology Research Foundation (MTTRF) for the availability of the Mori Seiki NT1000/W mill-turn center.

Funding

This work was partially supported by the Department of Mechanical Engineering at the Mus Alparslan University.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Faculty of Engineering, Abdullah Gul University, 38080, Kayseri, Turkey

    Sinan Kesriklioglu

Authors
  1. Sinan Kesriklioglu
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

The author is solely responsible for the following: study conception and design, data collection, analysis and interpretation of results, and manuscript preparation.

Corresponding author

Correspondence to Sinan Kesriklioglu.

Ethics declarations

Ethics approval

Not applicable.

Consent to participate

Not applicable.

Consent for publication

The author has consented to publish the research article in the journal.

Conflict of interest

Not applicable.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Kesriklioglu, S. Ineffectiveness of flood cooling in reducing cutting temperatures during continuous machining. Int J Adv Manuf Technol 122, 3957–3968 (2022). https://doi.org/10.1007/s00170-022-10093-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-10093-7

Keywords

Search

Navigation