Reduction of amount of cutting fluid in flood turning by finite element analysis

Abstract

In recent years, applying cutting fluids during machining operations has attracted immense scrutiny due to the adverse effects on human health and the environment. As a result, a large quantity of research has been undertaken worldwide to reduce the application of cutting fluids. This paper presents a new approach to reducing the amount of cutting fluid in flood machining by determining the amount of cutting fluid necessary for the job. The heat generation mechanism and its contributions to the workpiece, tool, and chips are examined, and the temperature rise of the tool is calculated with Finite Element Analysis (FAE) using the ANSYS CFX software package. The maximum permissible temperature was set as the tempering temperature of the cutting tool because at this temperature the cutting tool starts to lose its strength. The amount of cutting fluid adequate for a machining operation is determined by finding the intersection point between the temperature rise curve and the tempering temperature of the cutting tool. Finally, a graph illustrating the relationship between the flow rate of the cutting fluid and the heat that enters the cutting tool is presented which provides an estimate of the flow rate of the cutting fluid necessary for an arbitrary cutting condition