Research On Coupled Thermo-Mechanical Modeling And Testing Of Heat Pipe Cutter In Machining

Cutting fluid cooling method is often used to in the traditional cutting process to cool thecutting tool and workpiece, which can reduce the adverse effect of cutting heat in machining.There are lots of disadvantages by using cutting fluid, such as the utilization cost is too high,it can pollute environment and impair workers’ health, so the cutting fluid is be limited to usein many countries. The existing green cutting technology has not been spread and used due toits high cost and immature technology. It is a new concept in the dry cutting technology tobring the heat pipe into the structure design of cutting tool, the supernormal heat-transfercapability of heat pipe can be used to dissipate part of heat which highly localized in the toolbit.The methods of cutting measurement experiment and finite elements simulation are usedin this thesis to research the performance of heat pipe cutter under the affect of coupledthermol-mechanical in cutting process. Metal cutting experiments are firstly carried out byusing the prototype tool and three types of heat pipe cutter, and the cutting force, cuttingtemperature and tool-chip interface data of the four tools cutting#45steel in different cuttingparameter are measured. Then, the heat conducting experiments are carried out by using awelding power source to simulate the heated condition of cutting tool in cutting process, andthe method of inverse heat transfer resolving, which is used by a predecessor of researchgroup to solve the heat heat flux loaded on the tool-chip interface, is validated, and the errorbetween the experiment result and resolved result is within10%. And then, the correctness ofheat transfer finite element model of the cutting tool has been validated. After that, thecoupled thermol-mechanical finite element model of cutting tool is created by use of FEsoftware, and the temperature field, composited stress field and deformation of the tool incutting process are brought off, which the cutting force and cutting heat are loaded ontool-chip interface at the same time. Lastly, the heat dispersion of heat pipe cutter is evaluatedafter analyzing the maximum temperature, composited stress and deformation of cutting toolsin cutting, and after that, the design of heat pipe cutters are optimized.The result of measuring experiments and finite element numerical simulation andanalysis shows that, within the range of experimental conditions adopted in this thesis, the highest temperature of tool chip interface on heat pipe cutters is about21°C to108°C, whichthe maximum composited stress is1.2%to8.2%, and the maximum composited deformationis0.8%to6.9%lower than the common cutter in the same cutting parameters. It is provedthat the heat pipe cutters have a better performance on dissipating cutting heat and decreasingthe temperature, stress and deformation of tool bit.