TITLE

THERMAL ANALYSIS OF CUTTING TOOLS BY USING

DIFFERENT CUTTING FLUIDS
SUBMITED BY
M.DHANUNJAYA(133A1D1106)
T.S.E.S.
GLOBAL COLLEGE OF ENG & TECH.
GUIDED BY
G.V.NAGAMANI M.TECH, M.I.S.T.E.

ABSTRACT
Cutting fluids are used in machining operation for various reasons namely to improve tool
life, to reduce work-piece thermal deformation and to improve surface finish. The usage of appropriate
cutting fluids will not only reduces cutting tool cost but also increases production; this is concluded
through Mota and Machado (1995).
Two main problems addressed by cutting fluids: Heat generation at shear zone and friction
zone, friction at the tool chip and tool work interfaces. Benefits and other functions of cutting fluids
such as wash away of chips for example milling and grinding, reducing temperature of work piece for
easier handling and also to improve dimensional stability of work part.
In this thesis soluble oil, water and palm kernel oil were used as coolants in machining operations.
Tungsten carbide and HSS cutting tools are employed as cutter with different temperatures. Thermal
analysis is done on the parametric model to determine the effect of different cutting fluids on the cutters.

INTRODUCTION
Milling is the process of cutting away of material by feeding a work piece past a rotating multiple
tooth cutter. Fast way of machining can be done through many teeth of the milling cutter. Through this
machining the surface may be curved, angular or flat and also can be milled to any type of required
shapes or any combination of shapes. The machine which grips the work piece, rotates the cutter, and
feeds the work part is called as the Milling machine
Solid materials are machined by the milling machine. The milling machines are categorized into two
simple forms horizontal and vertical, which depends on the alignment of the main spindle. These type
of milling machine have a collection of both small bench mounted devices to big size machines.
Unlike a drill press, which holds the work piece stationary as the drill moves axially to penetrate the
material, milling machines also move the work piece radially against the rotating milling cutter, which
cuts on its sides as well as its tip. The movements of work piece and cutter are exactly measured to
less than 0.001mm, these can be measured generally by means of precision ground slides and lead
screws or analogous technology. The milling machines can be operated manually, mechanically or
digitally through computer numerical control methods.

A vast number of performances can be done through milling machines from simple operation such as
keyway cutting , drilling, slot , planning etc., to complex performances for example die sinking,
contouring. The Cutting fluid is send to the cutting operation location to cool and lubricate the cut and
also to wash away of the resulting swarf which forms during operation.

INTRODUCTION TO MILLING CUTTERS

Milling cutters are cutting tools typically used in milling machines or machining centers (and
occasionally in other machine tools). By the movement of milling cutter these remove material
within the machine such as ball nose mill or directly from the cutter's shape such as a form tool
eg., a hobbling cutter.

The features of milling cutter

Two flutes of End Mill cutter

Milling cutters come in several shapes and many sizes. There is also a choice of coatings, as well
as rake angle and number of cutting surfaces.
Shape: Several standard shapes of milling cutter are used in industry today, which are explained
in more detail below.
Flutes / teeth: The flutes of the milling bit are the deep helical grooves running up the cutter,
while the sharp blade along the edge of the flute is known as the tooth. The tooth cuts the
material, and chips of this material are pulled up the flute by the rotation of the cutter. There is
almost always one tooth per flute, but some cutters have two teeth per flute. Often, the words
flute and tooth are used interchangeably. Milling cutters may have from one to many teeth, with
2, 3 and 4 being most common. Typically, the more teeth a cutter has, the more rapidly it can
remove material. So, a 4-tooth cutter can remove material at twice the rate of a 2-tooth cutter.
Helix angle: The flutes of a milling cutter are almost always helical. If the flutes were straight,
the whole tooth would impact the material at once, causing vibration and reducing accuracy and
surface quality. Setting the flutes at an angle allows the tooth to enter the material gradually,
reducing vibration. Typically, finishing cutters have a higher rake angle (tighter helix) to give a
better finish.

Center cutting: Some milling cutters can drill straight down (plunge) through the material, while
others cannot. This is because the teeth of some cutters do not go all the way to the centre of the end
face. However, these cutters can cut downwards at an angle of 45 degrees or so.
Roughing or Finishing: Different types of cutter are available for cutting away large amounts of
material, leaving a poor surface finish (roughing), or removing a smaller amount of material, but
leaving a good surface finish (finishing). A finishing cutter may have a large number (4 or more) teeth
for removing material carefully. However, the large number of flutes leaves little room for efficient
swarf removal, so they are less appropriate for removing large amounts of material.
Coatings: The right tool coatings can have a great influence on the cutting process by increasing
cutting speed and tool life, and improving the surface finish. Polycrystalline diamond (PCD) is an
exceptionally hard coating used on cutters which must withstand high abrasive wear. A PCD coated
tool may last up to 100 times longer than an uncoated tool. However the coating cannot be used at
temperatures above 600 degrees C, or on ferrous metals. Aluminum is a relatively sticky metal, and can
weld itself to the teeth of tools, causing them to appear blunt. However it tends not to stick to TiAlN,
allowing the tool to be used for much longer in aluminum.

Types

Slot, end mill, and ball nose cutters

End mills (middle row in image) are those tools which have cutting teeth at one end, as well as on
the sides.
The words end mill are generally used to refer to flat bottomed cutters, but also include rounded
cutters known as ball nose cutters and radii used cutters They are usually made from HSS or
carbide, and have one or more flutes. They are the most common tool used in a vertical mill.
Slot drill
Slot drills (top row in image) are center-cutting end mills, generally two- (sometimes three- or
four-) fluted cutters that are capable of drilling (plunge-cutting) straight down into the material
and then moving laterally to cut a slot. The plunge-cutting action is possible because at least one
(diametrically opposite) pair of teeth extend all the way to the centre of the end face. Such a
feature of end mills is called "center-cutting". Slot drills are so named for their use in cutting slots.

USING A MILLING CUTTER

Chip formation
Although there are many different types of milling cutter, understanding chip formation is fundamental
to the use of any of them. As the milling cutter rotates, the material to be cut is fed into it, and each
tooth of the cutter cuts away a small chip of material. Achieving the correct size of chip is of critical
importance. The size of this chip depends on several variables.
Surface cutting speed (Vc):
This is the speed at which each tooth cuts through the material as the tool spins. This is measured
either in metres per minute in metric countries, or surface feet per minute (SFM) in America. Typical
values for cutting speed are 10m/min to 60m/min for some steels, and 100m/min and 600m/min for
aluminum. This should not be confused with the feed rate. This value is also known as "tangential
velocity.
Spindle speed (S):
This is the rotation speed of the tool, and is measured in revolutions per minute (rpm). Typical values
are from hundreds of rpm, up to tens of thousands of rpm.

Feed per tooth (Fz):

This is the distance the material is fed into the cutter as each tooth rotates. This value is the size
of the deepest cut the tooth will make.
Feed rate (F):
This is the speed at which the material is fed into the cutter. Typical values are from 20mm/min
to 5000mm/min.
Depth of cut:
This is how deep the tool is under the surface of the material being cut (not shown on the
diagram). This will be the height of the chip produced. Typically, the depth of cut will be less
than or equal to the diameter of the cutting tool.

The machinist needs three values: S, F and Depth when deciding how to cut a new material with a
new tool. However, he will probably be given values of Vc and Fz from the tool manufacturer. S
and F can be calculated from them:

Spindle Speed

Feed rate

Looking at the formula for the spindle

In above formula feed rate, F displays that

speed, S, it can be seen that larger tools

increasing Speed or Z, depth gives a

require lower spindle speeds, while small

higher feed rate. Hence machinists can

tools may be able to go at high speeds

choose a tool with the utmost number of

teeth that can quiet manage with the swarf
load.

In order to create high quality and economical jobs a cutting tool needs the following features:
Hardness At higher temperatures the cutting tool must be upheld to get hardness and strength of
the cutting tool called as hot hardness
Toughness At the time carrying out operations toughness of cutting tools is required so that
tools dont chip or fracture, particularly at the period of interrupted cutting operations.
Wear Resistance It means that the execution of suitable tool life before tools must be
interchanged. Materials from which cutting tools are prepared are all normally hard and strong.
There is a extensive kind of tool materials existing for machining operations and the common
classification and application of these materials is interesting.
Tool Steels and Cast Alloys -It is the earlier to the tool materials dating 100s of years back. In
normal standings, it is a high carbon steel that holds nearly of 1.05% carbon. This great amount of
carbon content lets the steel to be more hardened, presenting higher resistance to abrasive wear.
The persistence of plain high carbon steel can be work well for several years. Though, as it is fastly
over tempered (softened) at quite low cutting temperatures of about 300 to 500F and it is at
present hardly ever used as cutting tool material excluding in files, saw blades, and chisels. The
application of plain high carbon steel is restricted to low heat uses.

High Speed Tool Steel-To resist high cutting speeds and temperatures the need for tool

materials directed to the advancement of HSS. The main variance between HSS and
plain high carbon steel is the accumulation of alloying components to harden and
strengthen the steel and create it further resistant to heat namely hot hardness
CLASSIFICATION OF CARBIDE MATERIALS
Products of cemented carbide are categorized into 3chief categories:
Wear Grades these are mainly used in dies, machine and tool guides and also used in normal
items such as line guides on fishing rods and reels. Good wear resistance is essential to custom it
anywhere.
Impact Grades These grades are used for dies, mainly for stamping and forming and also
used in tools namely mining drill heads.
Cutting Tool Grades these are of cemented carbides are classified into 2 groups, depending
on their principal usage. It is graded as a cast iron, if the carbide is planned for use on cast iron
that is a non-ductile material. it is categorized as steel grade carbide, if it is to be used to cut steel,
a ductile material.

INTRODUCTION TO PRO/ENGINEER
Pro/ENGINEER is a feature based, parametric solid modeling program. As such, it's use is
significantly different from conventional drafting programs.
In conventional drafting (either manual or computer assisted), various views of a part are
created in an attempt to describe the geometry.
Each view incorporates aspects of various features (surfaces, cuts, radii, holes, protrusions) but
the features are not individually defined.
In feature based modeling, each feature is individually described then integrated into the part.
The other significant aspect of conventional drafting is that the part geometry is defined by the
drawing.
If it is desired to change the size, shape, or location of a feature, the physical lines on the
drawing must be changed (in each affected view) then associated dimensions are updated.
When using parametric modeling, the features are driven by the dimensions (parameters).
To modify the diameter of a hole, the hole diameter parameter value is changed.
This automatically modifies the feature wherever it occurs - drawing views, assemblies, etc.
Another unique attribute of Pro/ENGINEER is that it is a solid modeling program.
The design procedure is to create a model, view it, assemble parts as required, then generate any
drawings which are required

Model of cutting tool using PROE

Model of work piece using PROE

GENERIC STEPS TO SOLVING ANY PROBLEM IN ANSYS

Like solving any problem analytically, you need to define (1) your solution domain, (2) the
physical model, (3) boundary conditions and (4) the physical properties. You then solve the
problem and present the results. In numerical methods, the main difference is an extra step called
mesh generation. This is the step that divides the complex model into small elements that become
solvable in an otherwise too complex situation. Below describes the processes in terminology
slightly more attune to the software
1.

Build geometry

2.

Define material properties

3.

Generate mesh

4.

Apply loads

5.

Obtain solution

6.

Present the solution


ANSYS is capable of both steady state and transient analysis of any solid with thermal boundary
conditions.
Steady-state thermal analyses calculate the effects of steady thermal loads on a system
orcomponent. Users often perform a steady-state analysis before doing a transient thermal
analysis, to help establish initial conditions. A steady-state analysis also can be the last step of a
transient thermal analysis; performed after all transient effects have diminished. ANSYS can be
used to determine temperatures, thermal gradients, heat flow rates, and heat fluxes in an object
that are caused by thermal loads that do not vary over time. Such loads include the following:

Convection

Radiation

Heat flow rates

A steady-state thermal analysis may be either linear, with constant material properties; or
nonlinear, with material properties that depend on temperature. The thermal properties of most
material vary with temperature. This temperature dependency being appreciable, the analysis
becomes nonlinear. Radiation boundary conditions also make the analysis nonlinear. Transient
calculations are time dependent and ANSYS can both solve distributions as well as create video
for time incremental displays of models.

ANALYSIS OF MILLING CUTTER

TRANSIENT ANALYSIS FOR HSS MATERIAL
Coolant - Kernel oil
Temperature - 410k
Nodal temperature

Thermal flux

Thermal gradient

Temperature - 460k
Nodal temperature

Temperature gradient

Thermal flux

Temperature 510k
Nodal temperature

Temperature gradient

Thermal flux

SOLUBLE OIL AS COOLANT

Temperature - 410k
Convection
Film co-efficient =0.09 W/mm2 K
Bulk Temperature 303K
Nodal temperature

Thermal flux

Thermal gradient

Temperature 460k

Nodal temperature

Thermal gradient

Thermal flux

Temperature - 510k
Nodal temperature

Thermal gradient

Thermal flux

WATER AS COOLANT
Temperature - 410k
Convection
Film co-efficient =0.0021 W/mm2 K
Bulk Temperature 303K
Nodal temperature

Thermal flux

Thermal gradient

Temperature 460k
Nodal temperature

Thermal flux

Thermal gradient

Temperature
510k
Nodal temperature

Thermal gradient

Thermal flux

THERMAL ANALYSIS FOR CARBIDE MATERIAL

Coolant - Kernel oil
Temperature 410k
Nodal temperature

Thermal flux

Thermal gradient

Temperature 460k
Nodal temperature

Thermal flux

Thermal gradient

Temperature 510k
Nodal temperature

Thermal flux

Thermal gradient

SOLUBLE OIL AS COOLANT

Temperature 410k
Nodal temperature

Thermal flux

Thermal gradient

Temperature 460k
Nodal temperature

Thermal flux

Thermal gradient

Temperature 510k
Nodal temperature

Thermal gradient

Thermal flux

COOLANT - WATER
Temperature 410k
Nodal temperature

Thermal flux

Thermal gradient

Temperature 460k
Nodal temperature

Thermal flux

Thermal gradient

Temperature
510k
Nodal temperature

Thermal flux

Thermal gradient

RESULT TABLES
HSS MATERIAL
Nodal temperature Thermal

KERNEL

SOLUABLE OIL

WATER

gradient Thermal flux

(K)

(K/mm)

(W/mm2)

410

149.914

2.84836

460

220.051

4.18097

510

290.153

5.51291

410

162.111

3.08011

460

237.448

4.51152

510

312.965

5.94633

410

87.744

1.66714

460

72.801

1.38322

510

68.8123

1.30743

Properties of HSS material

CARBIDE MATERIAL
Nodal temperature Thermal

KERNEL

SOLUABLE OIL

WATER

gradient Thermal flux

(K)

(K/mm)

(W/mm2)

410

140.703

3.9397

460

206.209

5.77386

510

271.814

7.61086

410

145.858

4.08402

460

213.781

5.98588

510

281.802

7.89016

410

66.4684

1.86111

460

55.1176

1.54329

510

52.1571

1.4604

Properties of Carbide material

GRAPHS
CUTTING FLUID KERNEL
CUTTING TOOL MATERIAL Vs THERMAL GRADIENT (K/mm) AT DIFFERENT CUTTING TEMPERATURES
350
300
250
200

410

THERMAL GRADIENT (K/mm) 150

460
510

100
50
0
HSS

CARBIDE
CUTTING TOOL MATERIAL

CUTTING TOOL MATERIAL Vs THERMAL FLUX (W/mm2) AT DIFFERENT CUTTING TEMPERATURES

8
7
6
5

410

THERMAL FLUX (W/mm2) 4

3

460
510

2
1
0
HSS

CARBIDE
CUTTING TOOL MATERIAL

CUTTING FLUID - SOLUBLE OIL

CUTTING TOOL MATERIAL Vs THERMAL GRADIENT (K/mm) AT DIFFERENT CUTTING TEMPERATURES
350
300
250
410

200
THERMAL GRADIENT (K/mm)

460

150

510

100
50
0
HSS

CARBIDE
CUTTING TOOL MATERIAL

CUTTING TOOL MATERIAL Vs THERMAL FLUX (W/mm2) AT DIFFERENT CUTTING TEMPERATURES

9
8
7
6
5

410

THARMAL FLUX (W/mm2) 4

460

510

2
1
0
HSS

CARBIDE
CUTTING TOOL MATERIAL

CUTTING FLUID - WATER

CUTTING TOOL MATERIAL Vs THERMAL GRADIENT (K/mm) AT DIFFERENT CUTTING TEMPERATURES

THERMAL GRADIENT (K/mm)

100
90
80
70
60
50
40
30
20
10
0
HSS

410
460
510

CARBIDE
CUTTING TOOL MATERIAL

CUTTING TOOL MATERIAL Vs THERMAL FLUX (W/mm2) AT DIFFERENT CUTTING TEMPERATURES

THERMAL FLUX (W/mm2)

2
1.8
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
HSS

410
460
510

CARBIDE
CUTTING TOOL MATERIAL

CUTTING TOOL - HSS

CUTTING FLUID Vs THERMAL GRADIENT (K/mm) AT DIFFERENT CUTTING TEMPERATURES
350
300
250
200

410

THERMAL GRADIENT (K/mm) 150

460

100

510

50
0
Kernal

Soluble Oil

Water

CUTTING FLUIDS

CUTTING FLUID Vs THERMAL FLUX (W/mm2) AT DIFFERENT CUTTING TEMPERATURES

7
6
5
4
THERMAL
FLUX (W/mm2)
3
2
1
0
Kernal

Soluble Oil
CUTTING FLUIDS

Water

410
460
510

CUTTING TOOL - CARBIDE

CUTTING FLUID Vs THERMAL GRADIENT (K/mm) AT DIFFERENT CUTTING TEMPERATURES

300
250

410

200

460

150 GRADIENT (K/mm)

THERMAL
100

510

50
0
Kernal

Soluble Oil

Water

CUTTING FLUIDS

CUTTING FLUID Vs THERMAL FLUX (W/mm2) AT DIFFERENT CUTTING TEMPERATURES

AL FLUX (W/mm2)

10
8
6

410

460
510

2
0
Kernal

Soluble Oil
CUTTING FLUIDS

Water

CONCLUSION
In this thesis soluble oil, water and palm kernel oil were used as coolants in machining operations.
Tungsten carbide and HSS cutting tools are employed as cutter with different temperatures. Thermal
analysis is done on the parametric model to determine the effect of different cutting fluids on the
cutters.
Parametric Modeling is done in Pro/Engineer and analysis is done in Ansys.
By observing the analysis results, the heat transfer rates are more when the fluid Soluble oil is used
since thermal flux is more than Kernel and water. Kernel also has good heat transfer rates, but using
water is not preferable.
When compared the values for tool materials, the heat transfer rates are more for carbide tool than
HSS tool.

BIBILOGRAPHY
1. The Measurement of chip-tool interface Temperature in the Turning of steel by L. B.
Abhang, M. Hameedullah, International Journal of Computer Communication and Information
System ( IJCCIS), Vol2. No1. ISSN: 09761349 July to Dec 2010
2. Effect of tool geometry variation on finish turning A Review by M. Dogra,V. S. Sharma, J.
Dureja Journal of Engineering, Science and Technology Review no. 4 (1) (2011) 1-13.
3. Response Surface Method to Optimize the Turning Process of steel AISI 12L14.

Thank you