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A novel numerical modeling approach to determine the temperature distribution in the cutting tool using conjugate heat transfer (CHT) analysis
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology.
University of Guelph, CANADA.
Mechanical Engineering, American University of Sharjah.
KTH, School of Industrial Engineering and Management (ITM), Production Engineering, Machine and Process Technology.ORCID iD: 0000-0002-5960-2159
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2015 (English)In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 80, no 5, 1039-1047 p.Article in journal (Refereed) Published
Abstract [en]

This study deals with the conjugate heat transfer problem of a single point cutting tool under turning operation dissipating heat in the tool material and streams of the surrounding air. In order to estimate the cutting temperature during the turning operation, the DEFORM-3D finite element package was utilized. A machining simulation material model for Ti6Al4V was utilized using a modified Johnson–Cook equation. The maximum cutting temperature value was obtained from the finite element model. The temperature was then used as a constant heat source on the tool tip, and the conjugate heat transfer (CHT) approach was used to develop a computational fluid dynamics (CFD) model. The CFD model utilized a 3D heat and fluid flow analysis using ANSYS ® CFX. A cutting insert with a constant heat source was exposed to the stream velocities of the dry air. The numerical equations governing the flow and thermal fields in the fluid domain and energy equation in the solid domain were solved in parallel by maintaining the continuity of temperature and heat flux at the solid–fluid interface. The presented conjugate heat transfer (CHT) approach provided a very useful understanding of the temperature profile development at the cutting tool that is still a complex challenge for the existing experimental and numerical techniques.

Place, publisher, year, edition, pages
Springer, 2015. Vol. 80, no 5, 1039-1047 p.
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
Production Engineering
Identifiers
URN: urn:nbn:se:kth:diva-173586DOI: 10.1007/s00170-015-7086-2ISI: 000360700900026Scopus ID: 2-s2.0-84949999119OAI: oai:DiVA.org:kth-173586DiVA: diva2:853729
Note

QC 20150915

Available from: 2015-09-14 Created: 2015-09-14 Last updated: 2017-12-04Bibliographically approved
In thesis
1. Numerical and Experimental Investigations of the Machinability of Ti6AI4V: Energy Efficiency and Sustainable Cooling/ Lubrication Strategies
Open this publication in new window or tab >>Numerical and Experimental Investigations of the Machinability of Ti6AI4V: Energy Efficiency and Sustainable Cooling/ Lubrication Strategies
2015 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Titanium alloys are widely utilized in the aerospace, biomedical,marine, petro-chemical and other demanding industries due to theirdurability, high fatigue resistance and ability to sustain elevateoperating temperature. As titanium alloys are difficult to machine, dueto which machining of these alloys ends up with higher environmentalburden. The industry is now embracing the sustainable philosophy inorder to reduce their carbon footprint. This means that the bestsustainable practices have to be used in machining of titanium alloys aswell as in an effort to reduce the carbon footprint and greenhouse gas(GHG) emissions.In this thesis, a better understanding towards the feasibility of shiftingfrom conventional (dry and flood) cooling techniques to the vegetableoil based minimum quantity cooling lubrication (MQCL) wasestablished. Machining performance of MQCL cooling strategies wasencouraging as in most cases the tool life was found close to floodstrategy or sometimes even better. The study revealed that theinfluence of the MQCL (Internal) application method on overallmachining performance was more evident at higher cutting speeds. Inaddition to the experimental machinability investigations, FiniteElement Modeling (FEM) and Computational Fluid Dynamic (CFD)Modeling was also employed to prediction of energy consumed inmachining and cutting temperature distribution on the cutting tool. Allnumerical results were found in close agreement to the experimentaldata. The contribution of the thesis should be of interest to those whowork in the areas of sustainable machining.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2015. xx, 136 p.
Series
TRITA-IIP, ISSN 1650-1888 ; 15:07
Keyword
Titanium alloys, Energy consumption, Wear mechanisms, Finite element analysis, computational fluid dynamic analysis
National Category
Production Engineering, Human Work Science and Ergonomics
Research subject
Production Engineering
Identifiers
urn:nbn:se:kth:diva-173594 (URN)978-91-7595-702-9 (ISBN)
Public defence
2015-10-01, Brinellsal M311, Brinellvägen 68, KTH, Stockholm, 10:00 (English)
Opponent
Supervisors
Note

QC 20150915

Available from: 2015-09-15 Created: 2015-09-15 Last updated: 2015-09-15Bibliographically approved

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Rashid, Amir

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