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Thermal analysis of a proposed internally cooled machining tool system

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Abstract

Due to the increase in environmental degradation, industries are forced to work with less harmful manufacturing means. In machining, it is known that one of the best ways to preserve cutting tool life is by using cutting fluids. However, even if this component proves to be effective, its use is still questionable because it strongly contributes to environmental degradation. For many years, several researchers have been looking for new ways to minimize this problem or even eliminate the use of cutting fluids, including the application of coatings in the cutting tool, more ecological coolants or alternative cooling methods. This work presents a thermal study of a proposed cooling technique for machining based on a cutting tool and tool holders designed with internal cooling channels, where a fluid circulates in a closed cycle called internally cooled tool (ICT). It studies the effect that the ICT technique has on the machining temperatures. This proposal can be considered ecologically less harmful because it saves the use of cutting fluids. To investigate the behavior of the system, gray iron was machined using the ICT made of cemented carbide. The response variable was the temperatures generated during cutting, measured by the tool-workpiece thermocouple system and welded thermocouple methods. Input parameters were the cutting speed and machining atmosphere conditions (dry, ICT using water at room temperature and ICT using chilled water). The ICTs reduced up to 21.52% of the temperature at the chip-tool interface compared to the dry machining process and showed a significant impact on the thermal gradients in the cutting tool and tool holder.

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Data availability

The datasets obtained during the current work are available from the corresponding author upon request.

Abbreviations

CF:

Cutting fluids

CO2 :

Carbon dioxide

DOE:

Design of experiment

e.m.f.:

Electromotive force

ICT:

Internally cooled tools

LN2 :

Liquid nitrogen

MQL:

Minimum quantity of lubricant

PHE:

Primary heat exchanger

REDM:

Rotating electrical discharge machining

SHE:

Secondary heat exchanger

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Acknowledgements

The authors are grateful to Tupy S.A. for providing the work material, to Walter Tools for donating the tools, and to Nipo-Tec Ferramentas Industriais for designing and machining the channels of the ICTs inserts by REDM.

Funding

This study was funded by the Brazilian research agencies CNPq, FAPEMIG, and Coordenação de Aperfeiçoamento de Pessoal de Nível Superior—Brasil (CAPES)—Finance Code 001.

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Authors and Affiliations

  1. Federal University of Uberlândia - UFU, 2121 João Naves de Ávila Avenue, Uberlândia, 38408-100, Brazil

    Pedro Henrique Pires França, Lucas Melo Queiroz Barbosa, Gustavo Henrique Nazareno Fernandes, Leonardo Rosa Ribeiro da Silva, Álisson Rocha Machado & Márcio Bacci da Silva

  2. Mechanical Engineering Graduate Program, Pontifícia Universidade Católica do Paraná–PUCPR, Rua Imaculada Conceição, 1155, Curitiba, PR, 80215-901, Brazil

    Álisson Rocha Machado

  3. Pontifícia Universidade Católica de Minas Gerais – PUC-MG, 500 Dom José GasparAvenue, Belo Horizonte, 30535-610, Brazil

    Paulo Sérgio Martins

  4. Stellantis, Av Do Contorno da Fiat, 3455, Betim, MG, 32530-490, Brazil

    Paulo Sérgio Martins

Authors
  1. Pedro Henrique Pires França
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  2. Lucas Melo Queiroz Barbosa
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Correspondence to Pedro Henrique Pires França.

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França, P.H.P., Barbosa, L.M.Q., Fernandes, G.H.N. et al. Thermal analysis of a proposed internally cooled machining tool system. Int J Adv Manuf Technol 124, 2807–2821 (2023). https://doi.org/10.1007/s00170-022-10602-8

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