Experimental and computational analysis of the coolant distribution considering the viscosity of the cutting fluid during machining with helical deep hole drills

doi:10.1007/s40436-021-00383-w

Advances in Manufacturing ›› 2022, Vol. 10 ›› Issue (2): 235-249.doi: 10.1007/s40436-021-00383-w

Experimental and computational analysis of the coolant distribution considering the viscosity of the cutting fluid during machining with helical deep hole drills

Ekrem Oezkaya, Sebastian Michel, Dirk Biermann

Institute of Machining Technology, Dortmund University of Technology (TU Dortmund), Dortmund 44227, Germany

收稿日期:2021-04-25 修回日期:2021-06-13 发布日期:2022-06-11
通讯作者: Ekrem Oezkaya E-mail:ekrem.oezkaya@tu-dortmund.de
基金资助:
The authors gratefully acknowledge funding from the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) for the research project (Grant No. 317373968).

Experimental and computational analysis of the coolant distribution considering the viscosity of the cutting fluid during machining with helical deep hole drills

Ekrem Oezkaya, Sebastian Michel, Dirk Biermann

Institute of Machining Technology, Dortmund University of Technology (TU Dortmund), Dortmund 44227, Germany

Received:2021-04-25 Revised:2021-06-13 Published:2022-06-11
Contact: Ekrem Oezkaya E-mail:ekrem.oezkaya@tu-dortmund.de
Supported by:
The authors gratefully acknowledge funding from the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) for the research project (Grant No. 317373968).

摘要/Abstract

摘要： An experimental analysis regarding the distribution of the cutting fluid is very difficult due to the inaccessibility of the contact zone within the bore hole. Therefore, suitable simulation models are necessary to evaluate new tool designs and optimize drilling processes. In this paper the coolant distribution during helical deep hole drilling is analyzed with high-speed microscopy. Micro particles are added to the cutting fluid circuit by a developed high-pressure mixing vessel. After the evaluation of suitable particle size, particle concentration and coolant pressure, a computational fluid dynamics (CFD) simulation is validated with the experimental results. The comparison shows a very good model quality with a marginal difference for the flow velocity of 1.57% between simulation and experiment. The simulation considers the kinematic viscosity of the fluid. The results show that the fluid velocity in the chip flutes is low compared to the fluid velocity at the exit of the coolant channels of the tool and drops even further between the guide chamfers. The flow velocity and the flow pressure directly at the cutting edge decrease to such an extent that the fluid cannot generate a sufficient cooling or lubrication. With the CFD simulation a deeper understanding of the behavior and interactions of the cutting fluid is achieved. Based on these results further research activities to improve the coolant supply can be carried out with great potential to evaluate new tool geometries and optimize the machining process.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-021-00383-w

关键词: Computational fluid dynamics (CFD) analysis, Viscosity, Tracer micro particles, Fluid behavior, Helical deep hole drilling

Abstract: An experimental analysis regarding the distribution of the cutting fluid is very difficult due to the inaccessibility of the contact zone within the bore hole. Therefore, suitable simulation models are necessary to evaluate new tool designs and optimize drilling processes. In this paper the coolant distribution during helical deep hole drilling is analyzed with high-speed microscopy. Micro particles are added to the cutting fluid circuit by a developed high-pressure mixing vessel. After the evaluation of suitable particle size, particle concentration and coolant pressure, a computational fluid dynamics (CFD) simulation is validated with the experimental results. The comparison shows a very good model quality with a marginal difference for the flow velocity of 1.57% between simulation and experiment. The simulation considers the kinematic viscosity of the fluid. The results show that the fluid velocity in the chip flutes is low compared to the fluid velocity at the exit of the coolant channels of the tool and drops even further between the guide chamfers. The flow velocity and the flow pressure directly at the cutting edge decrease to such an extent that the fluid cannot generate a sufficient cooling or lubrication. With the CFD simulation a deeper understanding of the behavior and interactions of the cutting fluid is achieved. Based on these results further research activities to improve the coolant supply can be carried out with great potential to evaluate new tool geometries and optimize the machining process.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-021-00383-w

Key words: Computational fluid dynamics (CFD) analysis, Viscosity, Tracer micro particles, Fluid behavior, Helical deep hole drilling

Ekrem Oezkaya, Sebastian Michel, Dirk Biermann. Experimental and computational analysis of the coolant distribution considering the viscosity of the cutting fluid during machining with helical deep hole drills[J]. Advances in Manufacturing, 2022, 10(2): 235-249.

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Experimental and computational analysis of the coolant distribution considering the viscosity of the cutting fluid during machining with helical deep hole drills

Experimental and computational analysis of the coolant distribution considering the viscosity of the cutting fluid during machining with helical deep hole drills

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