Design and analysis of an internally cooled smart cutting tool for dry cutting

Abstract

Cutting fluid is traditionally used to remove heat generated during the cutting process, but it can cause environmental pollution, health hazards, and high cost of production. Dry cutting, without using the cooling liquid, is thus desirable and promising for the machining industry to produce components and products, both ecologically and more economically. In this paper, an internally cooled cutting tool for dry cutting is presented as a temperature-sensored smart cutting tool in its own right, with further applications for adaptive machining purposes. The cutting tool is characterized by a simple changeable internal cooling structure near the cutting tip. Simulations were performed to study the theoretical cooling efficiency and to optimize the cooling structure by combining it with the Taguchi Method. Furthermore, cutting trials were carried out to validate the novel cutting tool experimentally.