Manufacturing Rev. 5, 16 (2018)© M.S. Nagaraj et al., Published by EDP Sciences 2018https://doi.org/10.1051/mfreview/2018013

Available online at:https://mfr.edp-open.org

RESEARCH ARTICLE

Analysis of multipoint cutting tool temperature using FEMand CFDMeenaskshi Sundaram Nagaraj1,*, Chakaravarthy Ezhilarasan2, A. John Presin Kumar3, and Rishab Betala4

1 Department of Mechanical Engineering, Hindustan University, Chennai, India2 Department of Mechanical Engineering, SMK Fomra Institute of Technology, Chennai, India3 Department of Mechanical Engineering, Hindustan Institute of Technology and Science, Chennai, India4 ARE PEE Polymer, Gummidhipoodhi, India

* e-mail: n

This is an O

Received: 18 September 2018 / Accepted: 10 October 2018

Abstract.Nimonic C-263 is a British nickel–chromium–cobalt–molybdenum alloy specially meant to be used inhigh-temperature and high-strength applications. Consequently, it produces high thermo-mechanical loads onthemachining tool whenmachined. As a result, excessive heat is generated during dry drilling, betweenNimonicC-263 and tungsten carbide tool coated withAlcorna, which in turn reduces the durability of the tool. In order todetermine the temperature distribution of the tool, the coupling of finite element machining simulations alongwith computational fluid dynamics simulations is performed. The temperature distribution of the tool underdry condition is simulated via the DEFORM 3D software and the Altair AcuSolve software. Furtherinvestigation under cooling condition is performed using Altair AcuSolve software. The mass flow rate of thecoolants is kept constant when the temperature distribution is obtained during the CFD analysis under coolingcondition. Silver nano coolant has high heat reduction compared to other coolants and is found to generate 34%less heat than dry condition.

Keywords: Nimonic C-263 / finite element machining / CFD / coolant / temperature

1 Introduction

While drilling, super alloys such as Nimonic C-263 generatehigh heat on the cutting zone and high tool wear.Simulations are performed under external cooling con-ditions using varied coolants. The effect of external coolingis analyzed in the simulations and their effect on thetemperature distribution of the tool and the tool durabilityis also analyzed. Since the quantity of research conductedon external cooling of Nimonic C-263, and the effectivenessof the coolant is meager, we have conducted research in thisarea and have also analyzed and optimized the effect ofcoolant using this model. In AdvantEdge software, theboundary conditions for drilling are difficult to assign, andthe interface between the tool and workpiece is complicatedwhen compared to DEFORM 3D, and this leads toinstability in the result. The machining during dry con-dition is validated with experiment and simulations.

The research in Aerospace industries at present ishindered in cooling technology with respect to externaldrilling of super alloys.

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Salman et al. [1] proposed a technique to predict thetemperature profile of the cutting tool during machiningoperations via a coupled FE and CFD modeling approach.The finite element modeling and the CFD analysis wereperformed via DEFORM 2D software and ANSYS CFXsoftware. They simulated machining using Ti6Al4V anduncoated carbide as the workpiece and tool material,respectively. Air was utilized as a cooling media. Theproposed method was used in predicting the temperaturedistribution of the cutting tool under the influence of acoolant using the ANSYS CFX software.

Muhammad et al. [2] conducted a study to determinethe effect of cutting conditions such as feed rate and cuttingspeed on the temperature generated during the drillingprocess. They conducted the simulations using MSCMARCMENTAT on AISI 1010 steel and tungsten carbideas the tool material. The finite element simulations wereexperimentally verified using the drill bit on a lathe setup.The study concluded that there is an increase intemperature with respect to the increase in cutting speedand feed rate.

Fallenstein and Aurich [3] investigated the effect of thecutting fluid flow rate and cooling channel exit position intwist drills with internal cooling channels. They performed

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Fig. 1. Experimental setup.

2 M.S. Nagaraj et al.: Manufacturing Rev. 5, 16 (2018)

computational fluid dynamics simulations and found thatthe heat flux between the tool and coolant is influenced bythe cutting flow rate along with the cooling channel exitposition. Experiments with real flow conditions were alsoperformed and the results were similar to the resultsobtained in the computational fluid dynamics simulations.

Ekrem et al. [4] conducted a study to determine theeffect of coolant pressure and the coolant channeldiameter of the twist drill on tool life and bore qualitywhen drilling Inconel 718. Computational fluid dynamicssimulations were performed, and the results showed that ahigher mass flux of the coolant and the change in diameterof the coolant channel do not have any effect on the toollife, bore quality, and do not reduce the thermal loads. Butwhen the coolant pressures were increased, there was asignificant change in the tool life and the bore quality. Thesimulation results were corroborated with the experimen-tal results by drilling Inconel 718 and taking SEM imagesof the twist drill used.

Dahu et al. [5] performed a study to determine the toolwear when machining nickel-based super alloys. Theyanalyzed the tool life of various tools both coated anduncoated when machining Inconel 718. And they deter-mined that the tool life can be improved by appropriatelyselecting the tool geometry, tool materials, tool coating,and cutting parameters. Cooling and lubrication of the toolunder machining conditions have also been found toincrease the tool life.

Minton et al. [6] experimentally determined the effect ofcutting tool coating along with the use of internal cooledtools. They used diamond coated and uncoated cuttingtools along with internal cooling and uncooled conditions tomachine Titanium and found that heat extraction from thecutting was maximum when using diamond-coated drillswith internal cooling, the results were verified by usingthermal imaging cameras. They concluded that the use ofinternally cooled cutting tools along with indirect coolingshowed an increase in tool life.

Ramesh et al. [7] also conducted experiments to analyzethe effect of the cooling when drilling glass fiber-reinforcedepoxy composites. The experiments were conducted byusing TiN/TiAiN-coated tungsten carbide drills. Theyanalyzed the drill temperature and damage factor for drydrilling, internal, and external cooling conditions. Theyalso optimized the drilling conditions for both internal andexternal cooling conditions and reduced the drill tempera-ture by 53 and 81% for internal and external coolingconditions when compared to dry drilling.

Siller et al. [8] performed experiments to determine theheat dissipated during the turning operations by usinginternal cooled cutting tools. They measured the tempera-ture at the inlet and outlet of the cooling channels andfound that the temperature of the tool tip were lower thanthe temperature obtained during dry machining. Theyconcluded that by using the internal cooling, there was adefinitive decrease in tool life.

Kumar and Ahmed [9] experimentally compared theeffects of flood cooling with liquid nitrogen, when drillingAISI 304 stainless steel. The cutting temperature thrustforce and surface roughness under both cooling conditionswere analyzed. They concluded that when using liquid

nitrogen as a coolant, there was a decrease in cuttingtemperature by about 12–50%, and it also increased thethrust force by about 4–12%.

Attanasio et al. [10] simulated the tool wear using thefinite element machining simulation when drilling Inconel718. They used DEFORM 3D software to simulate themachining of Inconel 718. They concluded that tool wearincreases as the cutting time is increased. They alsoconducted experiments with the same parameters as usedin the simulation and found that the flank curves obtainedwere similar.

2 Simulation methodology

The coupled finite element machining simulations andcomputational fluid dynamics simulations are imple-mented in two stages accordingly. The first stage consistsof conventional finite element machining simulationconducted using the Johnson–Cook material model undertransient conditions. This modeling is executed usingDEFROM 3D software. The temperature distribution ofthe dry drill generated in the cutting tool point is obtainedin the first simulation stage.

The second stage consists of obtaining the temperaturedistribution from the dry drill condition as a heat source onthe cutting tool point of the drill. Under these conditions,the CFD analysis is performed using various coolants withconstant mass flow rate. There is a temperature reductionat the cutting tool point when various coolants are used.

3 Experimental result under dry condition

Drilling experiments were performed on Nimonic C-263alloy specimens of 70mm diameter and 10mm thicknesswith a hardness of 32 HRC. Drilling trials have beenconducted on ARIX (VMC 100) CNC vertical machiningcenter. The experimental setup is shown in Figure 1.Considering the abrasive nature of the Nimonic alloys andthe resultant generation of higher contact temperaturebetween tool and work interface, AlCrN-coated carbidedrills were selected and used for drilling the workpiece. Apyrometer was used to measure the temperature at the

Table 1. L27 orthogonal array.

Levels Control parameters Unit Levels

1 2 3

1 Spindle speed (N) rev/min 750 1000 12502 Feed rate (f) mm/rev 0.05 0.10 0.1253 Point angle (2r) ° 118 135 140

Table 2. Experimental results.

Exp.No.

Speed(rev/min)

Feedrate(mm/rev)

Pointangle(°)

Temperature(°C)

1 750 0.05 118 3752 750 0.05 135 4103 750 0.05 140 4754 750 0.10 118 4705 750 0.10 135 4806 750 0.10 140 5207 750 0.125 118 5508 750 0.125 135 5609 750 0.125 140 58510 1000 0.05 118 49011 1000 0.05 135 45512 1000 0.05 140 51013 1000 0.10 118 61014 1000 0.10 135 62015 1000 0.10 140 62016 1000 0.125 118 65517 1000 0.125 135 67518 1000 0.125 140 69019 1250 0.05 118 57520 1250 0.05 135 57521 1250 0.05 140 59022 1250 0.10 118 60023 1250 0.10 135 61024 1250 0.10 140 63525 1250 0.125 118 69526 1250 0.125 135 71527 1250 0.125 140 770

Table 3. Material property of Nimonic C-263.

Property Value

Density 8360 kg/m3

Young’s modulus 224 GPaPoisson’s ratio 0.3Cp 461 J/ kg °CShear factor 0.6

M.S. Nagaraj et al.: Manufacturing Rev. 5, 16 (2018) 3

cutting edge. Holes of 6mm have been drilled under dryconditions. L27 orthogonal array was chosen to carry outthe drilling trials. The experiments were conducted asshown in Table 1, using the L27 Array. During theexperimental trials, temperature of 635 °C was obtained atmaximum spindle speed of 1250 rpm and 0.1mm/revfeed rate. The temperature obtained in Deform 3D is640 °C. The temperature obtained is used to analyze theeffect of coolants using the simulations in DEFORM 3Dcoupled with CFD. The experimental results are shown inTable 2.

4 DEFORM 3D simulation under drycondition

The finite element model for machining is developed usingDEFORM 3D software with Nimonic C-263 as theworkpiece and tungsten carbide coated with Alcorna asthe tool material. The properties of the material are listedin Table 3. The flowmodel applied for Nimonic C-263 is theJohnson–Cook constitutive model. Equation (1) representsthe Johnson–Cook model. The shear friction model is usedto display the friction present at the tool-chip interface.The friction factor is 0.6 for tungsten carbide coated withAlcorna [11]. The Coulomb law is used for modeling thefriction force as shown in equation (2).

s ¼ AþBpn þ Cln _p_

_e_0

� �1� u � uR

um � uR

� �m� �� �; ð1Þ

where A=450 Mpa is the yield strength (MPa), B=1700MPa is the hardening modulus (MPa), C=0.017 is thestrain rate sensitivity coefficient, n=0.65 is the hardeningcoefficient, m=1.3 is the thermal coefficient, um=meltingtemperature, and uR= initial temperature.

fs ¼ mp: ð2ÞThe CAD model of the drill and the workpiece is meshedwith DEFORM 3D software as shown in Figure 2.The mesh properties are listed in Tables 4 and 5. Thefinite element machining model is used to determine thetemperature distribution of the drill bit under theboundary conditions. The workpiece is fixed, and the toolis rotated during the machining process under dry cuttingto determine the temperature distribution generated on thecutting tool. In FEA analysis, the machining parametersare as follows: spindle speed is 1250 rpm, feed rate is0.1mm/rev, and point angle is 140°. The result is obtainedin 5000 time-steps and the temperature of the cutting tool

Table 4. Drill bit parameters.

Drill bit diameter 6 mm

Point angle 140Mesh element TetrahedralMesh size 110 nodesRelative mesh size 35,000Size ratio 5

Fig. 2. Mesh of the drill and workpiece.

Fig. 3. Temperature distribution of the cutting tool.

Fig. 4. Chip removed during drilling with spindle speed=1250rpm, and feed rate=0.1mm/rev.

Table 5. Workpiece parameters.

Workpiece thickness 10 mm

Mesh element TetrahedralMesh size 110 nodesRelative mesh size 2400Size ratio 5

4 M.S. Nagaraj et al.: Manufacturing Rev. 5, 16 (2018)

obtained from the simulations is 640 °C as shown inFigure 3 and the corresponding chip removed during thedrilling process is shown in Figure 4. The temperatureobtained from the dry cutting condition is used as the heatsource on the drill point during second stage of thesimulation.

5 Altair AcuSolve simulation under coolingcondition

Altair AcuSolve CFD software is utilized to analyze thethermal effect of the heat generated during drillingand the effect of coolant on the tool temperature. TheAltair AcuSolve CFD software solves Navier–Stokesequations.

The Altair AcuSolve software yields automated mesh-ing solutions to reduce the pre-processing time. Thesoftware also provides a robust solution irrespective of themesh characteristics. Fully coupled pressure–velocity andtemperature–flow systems can be solved rapidly. CFDsimulation is done in AcuSolve solver and AcuSolve is builtaround the Navier–Stokes equations, which describe theproperties of viscous flows.

6 Methodology

The steps required to perform the simulation are genera-tion of a CADmodel, discretization of the CADmodel, anddefinition of the boundary conditions and materialproperties. The drill bit and workpiece CAD files areimported and meshed in Altair AcuSolve with the sameparameters used in the DEFORM 3D software as shown inFigure 5. The boundary condition considering the flow astransient state and Spalart–Allmaras model with arelaxation factor of 0.6 are as follows: Convective heattransfer coefficient is considered as 70W/m2K for the outerdrill bit and for the drill bit part that is inside the workpiececonsidered for 10W/m2K. The main settings for themeshing of solid and fluid domain are tetrahedrons withsizes ranging from 5e-4m to 3e-3m generating 10,71,906number of elements. The temperature distribution deter-mined from the DEFORM 3D simulation as 914K isassigned at the flank of the drill bit.

7 Cooling conditions

The drill bit is subjected to machining conditions bydrilling Nimonic C-263. The heat is generated due to the

Fig. 5. Mesh of the drill bit.

Table 6. Coolant properties.

Property Water Soluble oil Silver nano

Density 1000 kg/m3 981 kg/m3 1060 kg/m3

Cp 4185 J/kg K 4006 J/kg K 2841 J/kg KThermal conductivity 0.608W/mK 0.59W/mK 430W/m KViscosity 0.889 Ns/m2 1061e-6 Ns/m2 175 e-5 Ns/m2

Table 7. Change in temperature difference with respect to the coolant.

Coolant Temperature % Reduction in temperature

K °CAir 914 641Water 747 474 26.05%Oil 718 445 30.58%Nano 690 417 34.95%

M.S. Nagaraj et al.: Manufacturing Rev. 5, 16 (2018) 5

interaction between the flank of the drill and the chip. Thedrilling is subjected to cooling conditions by using coolantsuch as water, soluble oil, and nano fluids. The temperaturedistribution obtained from the dry cutting displays thatthe maximum temperature obtained is 914K and theminimum temperature is 294K. The drilling operation isperformed with different coolants with the same mass flowrate of 125ml/h feed rate of 0.1mm/rev and spindle speedof 1250 rpm.

The maximum flank temperature while using water,soluble oil, and nano are 747, 718, and 690K, respectively,

as shown in Figure 6. The properties of the various coolantsare given in Table 6. The percentage variation between thetemperatures is given in Table 7.

The simulations are performed under constant massflow rate to determine the percentage of temperaturereduction while using various coolants. When water is usedas a coolant during the drilling process, it is incapable totransport heat effectively because, during the machining ofNimonic C-263, there is high heat generated at the drill tipthat is of the magnitude of 640 °C, which is higher than theboiling point of water. Therefore, the water appliedevaporates without cooling the cutting zone and the heatis reduced by only 26% when compared to the drycondition. Further analysis is done using soluble oil, aviscous fluid. Soluble oil due to its high viscosity flowsbetween the drill flank and the workpiece; since themachining time is 5 s and themass flow rate of the coolant is125ml/h, the soluble oil is not capable of wetting thecutting zone and transporting heat away from the cuttingzone. The silver nano, on the other hand, has highwettability, resulting in high heat transfer rates betweenthe tool and workpiece, and thus the percentage of heatreduction is higher than both water and soluble oil.Therefore, the rate of heat dissipation is high, and the toollife is extended.

When coolants such as water or soluble oil are used,there is also a risk of overheating the drill bit, consequentlydamaging the drill. The utilization of silver nano coolantprevents overheating of the drill. There is also a decrease inthe friction between the tool and the workpiece due to thelow shear factor. This results in the decrease of cuttingforce, which further increases the tool life. Because of theseproperties, the silver nano coolant can be used in thedrilling of the Nimonic C-263 alloy.

Fig. 6. Flank temperature when using air (a), water (b), silver nano coolant (c), and soluble oil (d).

6 M.S. Nagaraj et al.: Manufacturing Rev. 5, 16 (2018)

8 Conclusion

When working under external cooling conditions, thetemperature distribution of the drill bit can be predictedusing finite element methods coupled with computationalfluid dynamics. This method can be applied for analyzingthe effect of various coolants on the temperature of the drillor any other machining process. The simulations also showa decrease in the temperature distribution of the drill whenmachining under the influence of various coolants. There isa minimum change of 26% and a maximum change of 34%when using water and silver nano, respectively, whencompared to the dry cutting conditions. There is also anincrease in tool life during the machining operation whenusing silver nano coolant. This is due to the low frictionbetween the tool and the workpiece. Thus, silver nano is themost efficient coolant for the heat, temperature distribu-tion, and tool life issues. The effectiveness of new coolantscan be analyzed for machining operations using this model.Aerospace industries can easily optimize the coolant for themachining conditions under external cooling for drilling ofsuper alloys.

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Cite this article as: M.S. Nagaraj, C. Ezilarasan, A. John Presin Kumar, Rishab Betala, Analysis of multipoint cutting tooltemperature using FEM and CFD, Manufacturing Rev. 5, 16 (2018)

Analysis of multipoint cutting tool temperature using FEM and CFD1 Introduction2 Simulation methodology3 Experimental result under dry condition4 DEFORM 3D simulation under dry condition5 Altair AcuSolve simulation under cooling condition6 Methodology7 Cooling conditions8 ConclusionReferences