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Investigation of the effects of cooling in hard turning operations

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Abstract

As a means to overcome the limitations of cutting fluids in machining, more and more attention is being paid to the internal cooling of cutting tools. The elevated cutting zone temperature in hard turning causes the instant boiling of coolant in the cutting zone, which pulls down the tool life and surface finish, by making thermal distortions and hence in most of the hard turning operations, the coolant is not used at all. The absence of coolant also reduces the tool life and surface finish to some extent. As an alternative solution to the direct application of coolant in the metal cutting zone to improve tool life and surface finish, the heat pipe cooling system is introduced in this investigation. A parametric study is conducted to analyze the effects of different heat pipe parameters such as diameter of heat pipe, length of heat pipe, magnitude of vacuum in the heat pipe and material of heat pipe. All these parameters are varied to three levels. In this analysis, it is assumed that the single point cutting tool is subjected to static heating in the cutting zone which verifies the analysis and feasibility of using heat pipe cooling in turning operations. The heat pipe parameters are optimized by using Taguchi’s Design of Experiments and a confirmation test is conducted by employing the heat pipe fabricated with the best values of parameters. The results of the confirmation test are compared with the previous experimental results. The comparison shows that the use of a heat pipe in hard turning operations reduces the temperature field by about 5%, improves tool life by reducing tool wear and improves surface finish significantly. The result of this analysis is applicable to define controlling parameters of heat pipes for optimal design and set-up for various related studies. The finite element analysis also shows that the temperature drops greatly at the cutting zone and that the heat flow to the tool is effectively removed when a heat pipe is incorporated.

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Abbreviations

mm:

millimeter

°C:

degrees centigrade

kJ:

kilojoule

m/min:

meter per minute

mm/rev:

millimeter per revolution

s:

second

V:

volt

VA:

volt-ampere

Hz:

hertz

AC:

alternating current

Cp :

specific heat

kW:

kilowatt

rpm:

revolutions per minute

mmHg:

millimeters of mercury

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Authors and Affiliations

  1. Department of Production Engg., National Institute of Technology, Thiruchirappalli, 620 015, Tamil Nadu, India

    A. Noorul Haq & T. Tamizharasan

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  1. A. Noorul Haq
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  2. T. Tamizharasan
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Correspondence to A. Noorul Haq.

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Noorul Haq, A., Tamizharasan, T. Investigation of the effects of cooling in hard turning operations. Int J Adv Manuf Technol 30, 808–816 (2006). https://doi.org/10.1007/s00170-005-0128-4

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  • DOI: https://doi.org/10.1007/s00170-005-0128-4

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