Investigation of Heat Pipe Cooling in Drilling Applications: Part 2—Thermal, Structural Static, and Dynamic Analyses

2009 ◽  
Author(s):  
Lin Zhu ◽  
Tien-Chien Jen ◽  
Chen-Long Yin ◽  
Yi-Hsin Yen ◽  
Mei Zhu ◽  
...  
Keyword(s):  
Heat Pipe ◽  
Tool Life ◽  
Cutting Temperature ◽  
Dimensional Accuracy ◽  
Mechanical Effect ◽  
Machining Process ◽  
Drilling Process ◽  
Dynamic Analyses ◽  
Thermal Wear ◽  
3D Finite Element Method

Drilling is a highly complex machining process coupled with thermo-mechanical effect. Both the rapid plastic deformation of the workpiece and the friction along the drill-chip interface can contribute to localized heating and increasing temperature in the workpiece and tool. The cutting temperature at the tool-chip interface plays an important role in determining the tool thermal wear. This in turn affects the dimensional accuracy of the workpiece and the tool life of drill. A new embedded heat pipe technology has been proven to be able to effectively not only remove the heat generated at the tool-chip interface in drilling, but also minimize pollution and contamination of the environment caused by cutting fluids. Less tool wear can then be achieved, thus prolonging the tool life. 3D Finite Element method using COSMOS/works is employed to study coupled effects of thermal, structural static and dynamic analyses in a drilling process to check the feasibility and effectiveness of the heat pipe drill. Four different cases, solid drill without coolant, solid drill with coolant, heat pipe drill, and heat pipe drill with coolant, are explored, respectively. The results from this study can be used to define geometric parameters for optimal designs.

Prediction of Temperature Distribution in High-Speed End Mill Assisted by Heat Pipe Cooling

2011 ◽  
Vol 311-313 ◽  
pp. 2371-2374
Author(s):  
Hua Wei Ju ◽  
Wei Xiao Tang ◽  
Qing Hua Song ◽  
Hong Liang Zhou
Keyword(s):  
Temperature Distribution ◽  
Heat Pipe ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Dimensional Accuracy ◽  
Machining Process ◽  
Clear Understanding ◽  
End Mill ◽  
Heat Transfer Theory

The cutting temperature is a key factor which directly affects thermal distortion, the machined part’s dimensional accuracy, as well as the tool wear in machining process. Aiming to effectively remove the cutting heat yields in machining process, the cutting tool with heat pipe cooling has been developed in recent years. This research focuses on developing a clear understanding of the temperature distribution in end mill embedded with heat pipe. Mathematical model is developed based on the heat transfer theory and the metal-cutting theory. 3-D finite element models are set up. The thermal boundary conditions are properly set, and contrasts of the temperature field in end mill with and without embedded heat pipes by numerical simulations are given.

Current Progresses of Laser Assisted Machining of Aerospace Materials for Enhancing Tool Life

2013 ◽  
Vol 690-693 ◽  
pp. 3359-3364
Author(s):  
Shou Jin Sun ◽  
Milan Brandt ◽  
John P.T. Mo
Keyword(s):  
Tool Life ◽  
Cutting Tool ◽  
State Of The Art ◽  
Aerospace Industry ◽  
Cutting Temperature ◽  
Machining Process ◽  
Metallic Materials ◽  
Aerospace Materials ◽  
Beam Position ◽  
Laser Assisted Machining

A higher strength and heat resistance are increasingly demanded from the advanced engineering materials with high temperature applications in the aerospace industry. These properties make machining these materials very difficult because of the high cutting forces, cutting temperature and short tool life present. Laser assisted machining uses a laser beam to heat and soften the workpiece locally in front of the cutting tool. The temperature rise at the shear zone reduces the yield strength and work hardening of the workpiece, which make the plastic deformation of the hard-to-machine materials easier during machining. The state-of-the-art, benefits and challenges in laser assisted machining of metallic materials are summarized in this paper, and the improvement of tool life is discussed in relation to laser power, beam position and machining process parameters.

scholarly journals Study of Manufacturing Process of Holes in Aeroengine Heat Shield

2019 ◽  
Vol 2019 ◽  
pp. 1-11
Author(s):  
Anyuan Jiao ◽  
Weijun Liu
Keyword(s):  
Cutting Temperature ◽  
Dimensional Accuracy ◽  
Aircraft Engine ◽  
Heat Shield ◽  
Drilling Process ◽  
High Plasticity ◽  
Processing Efficiency ◽  
Technical Parameters ◽  
Nickel Based Superalloy ◽  
Heat Shields

The nickel-based superalloy GH3128 with high plasticity, high long-lasting creep strength, good resistance to oxidation and stamping, and good welding performance is widely used in aircraft engine heat shields. The many holes that need to be machined on the heat shield are not only small in diameter but also dense, and GH3128 as a typical hard-to-process material has the problems of large cutting force, high cutting temperature, and serious hardening. Therefore, poor dimensional accuracy and residual burrs have become the main factors that limit the processing efficiency and processing quality. So, a novel combination of manufacturing processes was proposed. Firstly, laser cutting technology was used to process the base hole in a GH3128 plate, followed by reaming, and finally, using a magnetic abrasive finishing effector to remove burrs formed during the first two steps. The whole drilling process of the heat shields fully meets the requirements of the technical parameters. This study provides new reference for manufacturing the holes of a heat shield and other similar porous parts.

scholarly journals Analysis of the Performance of Drilling Operations for Improving Productivity

2021 ◽  
Author(s):  
Majid Tolouei-Rad ◽  
Muhammad Aamir
Keyword(s):  
High Speed ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Dimensional Accuracy ◽  
Vital Role ◽  
Machining Process ◽  
Drilling Process ◽  
Single Shot ◽  
Drilling Operations

Drilling is a vital machining process for many industries. Automotive and aerospace industries are among those industries which produce millions of holes where productivity, quality, and precision of drilled holes plays a vital role in their success. Therefore, a proper selection of machine tools and equipment, cutting tools and parameters is detrimental in achieving the required dimensional accuracy and surface roughness. This subsequently helps industries achieving success and improving the service life of their products. This chapter provides an introduction to the drilling process in manufacturing industries which helps improve the quality and productivity of drilling operations on metallic materials. It explains the advantages of using multi-spindle heads to improve the productivity and quality of drilled holes. An analysis of the holes produced by a multi-spindle head on aluminum alloys Al2024, Al6061, and Al5083 is presented in comparison to traditional single shot drilling. Also the effects of using uncoated carbide and high speed steel tools for producing high-quality holes in the formation of built-up edges and burrs are investigated and discussed.

A Review on Drilling Printed Circuit Boards

2011 ◽  
Vol 188 ◽  
pp. 441-449 ◽  
Author(s):  
L.J. Zheng ◽  
Cheng Yong Wang ◽  
Yue Xian Song ◽  
L.P. Yang ◽  
Y.P. Qu ◽  
...  
Keyword(s):  
Printed Circuit Boards ◽  
Cutting Temperature ◽  
Structure Design ◽  
Machining Process ◽  
Drilling Process ◽  
Circuit Boards ◽  
Tool Materials ◽  
Printed Circuit ◽  
Small Defect ◽  
Critical Issues

Drilling is a particularly complicated machining process, and it becomes much more complicated when the workpiece is printed circuit boards (PCBs). PCB is composite materials with anisotropy. Even a small defect in PCB may cause great losses. Both the drilling process and PCB structure design have been researched by many scholars. But the investigations into the drilling processes of PCB are not systematic. The present review article address the report about tool materials and geometrics, cutting force, cutting temperature, radial run-out and damages occurring in drilling processes. And as a conclusion, some of these critical issues are proposed to meet the challenges in analysis and optimization for PCB drilling.

Cutting temperature, tool wear, and tool life in heat-pipe-assisted end-milling operations

2014 ◽  
Vol 72 (5-8) ◽  
pp. 995-1007 ◽  
Author(s):  
Lin Zhu ◽  
Shuang-Shuang Peng ◽  
Cheng-Long Yin ◽  
Tien-Chien Jen ◽  
Xi Cheng ◽  
...  
Keyword(s):  
Tool Wear ◽  
Heat Pipe ◽  
Tool Life ◽  
End Milling ◽  
Cutting Temperature ◽  
Milling Operations

The Effect of an Embedded Heat Pipe in a Cutting Tool on Temperature and Wear

2003 ◽  
Author(s):  
Richard Y. Chiou ◽  
Jim S. J. Chen ◽  
Lin Lu ◽  
Mark T. North
Keyword(s):  
Heat Pipe ◽  
Tool Life ◽  
Cutting Tool ◽  
Tool Material ◽  
Dimensional Accuracy ◽  
Chip Color ◽  
Radius Of Curvature ◽  
Skin Exposure ◽  
Fundamental Understanding ◽  
Cutting Tool Insert

This paper presents the fundamental understanding of the effect of an embedded heat pipe in a cutting tool on temperature and wear in machining. In particular, the technique can effectively minimize pollution and contamination of the environment caused by cutting fluids and the health problems of skin exposure and particulate inhalation in manufacturing. The temperature of a tool plays an important role in thermal distortion and the machined part’s dimensional accuracy, as well as in tool life in machining. A new embedded heat pipe technology has been developed to effectively remove the heat generated at the tool-chip interface in machining, thereby reduce tool wear and prolong tool life. Experiments were carried out to characterize the temperature distributions when performing turning experiments using a cutting tool installed with an embedded heat pipe. The ANSYS simulations show that the temperature near the cutting edge drops significantly with an embedded heat pipe during machining. Temperature measurements at several locations on the cutting tool insert agree with the simulation results both with and without the heat pipe. The effect of the heat pipe on reducing the cutting tool temperature was further supported by the observations of cutting tool material color, chip color, and chip radius of curvature.

scholarly journals Parametric optimization of non-traditional machining processes using Taguchi method and super ranking concept

2019 ◽  
Vol 29 (2) ◽  
pp. 249-271 ◽  
Author(s):  
Partha Das ◽  
Shankar Chakraborty
Keyword(s):  
Taguchi Method ◽  
Optimization Technique ◽  
Dimensional Accuracy ◽  
Optimization Techniques ◽  
Machining Process ◽  
Simultaneous Optimization ◽  
Drilling Process ◽  
Regression Equations ◽  
Machining Processes ◽  
Electro Discharge Machining

In order to achieve higher dimensional accuracy along with better surface quality, the conventional machining processes have now-a-days being replaced by non-traditional machining (NTM) processes, because of their ability to generate intricate shape geometries on various advanced engineering materials. In order to exploit their fullest machining potential, it is often recommended to operate those NTM processes at their optimal parametric settings. Several optimization tools and techniques are now available which can be effectively applied to obtain the optimal parametric conditions of those processes. In this paper, Taguchi method and super ranking concept are integrated together to present an efficient optimization technique for simultaneous optimization of three NTM processes, i.e. electro-discharge machining process, wire electro-discharge machining process and electro-chemical discharge drilling process. The derived results are validated with the help of developed regression equations, which show that the proposed approach outperforms the other popular multi-response optimization techniques. Analysis of variance is also performed to identify the most influencing control parameters for the considered NTM processes. The developed response surface plots further help the process engineers in identifying the effects of various NTM process parameters on the calculated sum of squared rank values.

Performance Evaluation of Cryogenic Treated and Untreated Carbide Inserts during Machining of AISI 304 Steel

2020 ◽  
Vol 17 (1) ◽  
pp. 7709-7718
Author(s):  
Nagraj Patil ◽  
K. Gopalakrishna ◽  
B. Sangmesh
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Cutting Tool ◽  
Cryogenic Treatment ◽  
Multilayer Coating ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Aisi 304 ◽  
Aisi 304 Steel

The cutting tool in the machining process plays an important role as it acts on the working material. There are a few methodologies have been persued to improve tool life, for example traditional cooling, single layer coating, multilayer coating, heat treatment process, nitrogen cooling and latest being the cryogenic treatment which reported a significant improvement in cutting tool life, chip morphology, reduction in heat generation. Hence, the cryogenic treatment is emerged as the sustainable machining process.  This paper presents machining of AISI 304 steel using both cryogenic treated (CT) and untreated (UT) cutting tool insert. The commercially available uncoated carbide insert has been cryogenically treated at -196°C for 24 hours soaking period. The machining test has been  conducted under four different cutting speeds. The material characterization of cutting insert is studied by using scanning electron microscopy (SEM), hardness test, and microscopic image analysis has been carried out before and after cryogenic treatment. The cutting tool performance is assessed in terms of of wear, cutting temperature, chip morphology, surface roughness under the influence of cryogenic machining and the results are contrast with UT one. The exploratory findings reveals that the deep cryogenic treatment (DCT) with 24 hours soaking period, performed better wear resistance and improved surface roughness of the cutting tool. Also considerable reduction in the flank wear, crater wear, cutting temperature is obtained and found improved chip morphology.

The Development of New Turning Tool for Cryogenic Machining

2020 ◽  
Author(s):  
Yongqing Wang ◽  
Haibo Liu ◽  
Yongquan Gan ◽  
Lingsheng Han ◽  
Kuo Liu ◽  
...  
Keyword(s):  
Tool Life ◽  
Surface Integrity ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Polymer Materials ◽  
Machining Process ◽  
Spray Angle ◽  
Cryogenic Machining ◽  
Injection Angle

Abstract Cryogenic manufacturing processes have emerged as environmental-friendly, increase tool life and improve surface integrity of machined components by efficiently removing the heat from the cutting zone. Especially considered to be an efficient method to machine difficult-to-cut metals which are poor thermal conductivity, such as nickel, titanium alloys and polymer materials and so on. Many researchers have studied the effectiveness of cryogenic machining process, such as increasing tool life and improving surface integrity and so on. However, most articles on this topic were not considered the applications of actual industry. Cutting tool is one of the most important parts of industry applications. Most of cutting tools were not designed for cryogenic machining. In this work, the internally cooled turning tool was developed for cryogenic machining. The spray angle and diameter of the outlet were optimized by thermal field simulations. The results showed that 15° injection angle was more suitable to the machining process. Compare to 1mm outlet diameter, 3mm outlet diameter had better cooling effect. And the shape of outlet was optimized. A pressure simulation of the inner channel is carried out. The result shows that the pressure drop from inlet to outlets is only 66.696277Pa (about 6‰). Then, a spray test of the cutting tool was performed. The tests revealed that liquid nitrogen could be transmitted accurately and stably to the tool nose and the machining area. At last, a machining experiment proved that the turning tool could reduce the cutting temperature effectively when machining Ti-6Al-4V.

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