Design and fabrication of an aluminium oxide cutting insert with an internal cooling channel

doi:10.1007/s40436-024-00483-3

Advances in Manufacturing ›› 2024, Vol. 12 ›› Issue (4): 619-641.doi: 10.1007/s40436-024-00483-3

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Design and fabrication of an aluminium oxide cutting insert with an internal cooling channel

John O'Hara¹, Feng-Zhou Fang^1,2

1. Centre of Micro/Nano Manufacturing Technology (MNMT-Dublin), University College Dublin, Dublin 4, Ireland;
2. State Key Laboratory of Precision Measuring Technology and Instruments, Laboratory of Micro/Nano Manufacturing Technology (MNMT), Tianjin University, Tianjin, 300072, People's Republic of China

收稿日期:2023-07-09 修回日期:2023-09-04 发布日期:2024-12-06
通讯作者: Feng-Zhou Fang,E-mail:fengzhou.fang@ucd.ie E-mail:fengzhou.fang@ucd.ie
作者简介:John O’Hara received his Ph.D in Mechanical and Materials Engineering at the Centre of Micro/Nano Manufacturing Technology (MNMT-Dublin) in University College Dublin. He is a chartered engineer (CEng) through the Institute of Materials Minerals and Mining (MIMMM), and a chartered physicist (CPhys) through the Institute of Physics (MInstP). He is also a registered European Engineer (EUR ING) through the UK Engineering Council. His interests include additive manufacturing, precision engineering, machine technology, thermodynamics, and ceramic engineering. Feng-Zhou Fang is a joint Professor and the director of Centre of Micro/Nano Manufacturing Technologies (MNMT) at Tianjin University and University College Dublin. He recieved his Ph.D in Manufacturing Engineering from the Harbin Institute of Technology and has been working in the field of manufacturing since 1982. He has conducted both fundamental studies and application development in the areas of micro-/nano machining, optical freeform design and manufacturing, and ultra-precision machining and measurement benefiting a variety of industries in medical devices, bio-implants, optics and mold sectors.
基金资助:
This publication has emanated from research conducted with the financial support of Science Foundation Ireland (Grant No.15/RP/B3208). The acknowledgement also goes to the “111” Project by the State Administration of Foreign Experts Affairs and the Ministry of Education of China (Grant No. B07014).

Design and fabrication of an aluminium oxide cutting insert with an internal cooling channel

John O'Hara¹, Feng-Zhou Fang^1,2

1. Centre of Micro/Nano Manufacturing Technology (MNMT-Dublin), University College Dublin, Dublin 4, Ireland;
2. State Key Laboratory of Precision Measuring Technology and Instruments, Laboratory of Micro/Nano Manufacturing Technology (MNMT), Tianjin University, Tianjin, 300072, People's Republic of China

Received:2023-07-09 Revised:2023-09-04 Published:2024-12-06
Contact: Feng-Zhou Fang,E-mail:fengzhou.fang@ucd.ie E-mail:fengzhou.fang@ucd.ie
Supported by:
This publication has emanated from research conducted with the financial support of Science Foundation Ireland (Grant No.15/RP/B3208). The acknowledgement also goes to the “111” Project by the State Administration of Foreign Experts Affairs and the Ministry of Education of China (Grant No. B07014).

摘要/Abstract

摘要： This paper presents the design and fabrication of an aluminium oxide cutting insert with an internal cooling channel formed through an additive manufacturing method. The formed insert is subjected to a controlled densification process and analysed through a series of characterisation investigations. The purpose of the study is to develop the design concept and analyse the forming and sintering parameters used in the lithographic ceramic manufacturing process. The results validated the feasibility of the geometrical design, providing the required structural conformity with the integrated internal feature using conditional specifications. It is confirmed that the forming parameters would affect the material properties of the green body. Furthermore, the results indicate that the heating rate and temperature variance of the de-binding and thermal treatment regime influences the microstructural growth kinetics and the quality of the densified insert. Using a novel application of liquid gallium as an internal coolant, experimental results showed a decrease in tool wear difference of 36% at V_c=250 m/min, and 31% in tool wear difference at V_c=900 m/min between cooling and non-cooling conditions. When external cooling was applied, the results showed at V_c=250 m/min, the difference between the tool wear rates with the internal coolant relative to the external coolant was 29%. Increasing to V_c=900 m/min, the results revealed a 16% tool wear difference. The results clearly indicate the potential of liquid gallium as a heat transfer agent in internal cooling applications for cutting inserts, and by extension demonstrable reduction in tool wear.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00483-3

关键词: Additive manufacturing (AM), Aluminium oxide, Cutting insert design, Internal cooling

Abstract: This paper presents the design and fabrication of an aluminium oxide cutting insert with an internal cooling channel formed through an additive manufacturing method. The formed insert is subjected to a controlled densification process and analysed through a series of characterisation investigations. The purpose of the study is to develop the design concept and analyse the forming and sintering parameters used in the lithographic ceramic manufacturing process. The results validated the feasibility of the geometrical design, providing the required structural conformity with the integrated internal feature using conditional specifications. It is confirmed that the forming parameters would affect the material properties of the green body. Furthermore, the results indicate that the heating rate and temperature variance of the de-binding and thermal treatment regime influences the microstructural growth kinetics and the quality of the densified insert. Using a novel application of liquid gallium as an internal coolant, experimental results showed a decrease in tool wear difference of 36% at V_c=250 m/min, and 31% in tool wear difference at V_c=900 m/min between cooling and non-cooling conditions. When external cooling was applied, the results showed at V_c=250 m/min, the difference between the tool wear rates with the internal coolant relative to the external coolant was 29%. Increasing to V_c=900 m/min, the results revealed a 16% tool wear difference. The results clearly indicate the potential of liquid gallium as a heat transfer agent in internal cooling applications for cutting inserts, and by extension demonstrable reduction in tool wear.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00483-3

Key words: Additive manufacturing (AM), Aluminium oxide, Cutting insert design, Internal cooling

John O'Hara, Feng-Zhou Fang. Design and fabrication of an aluminium oxide cutting insert with an internal cooling channel[J]. Advances in Manufacturing, 2024, 12(4): 619-641.

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Design and fabrication of an aluminium oxide cutting insert with an internal cooling channel

Design and fabrication of an aluminium oxide cutting insert with an internal cooling channel

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