Numerical investigations on effect of textured tools on heat transfer during machining.

The localization of heat in the machining zone of hard to cut materials leads to tool wear and increased surface roughness. Cutting fluids are used to minimize these effects, but their use is discouraged due to their detrimental effects on human health and environment. One of the potential solutions to reduce the use of cutting fluids is surface texturing on machining tools. Available literatures have mainly focused on tool wear reduction aspect only and there is a literature gap regarding quantitative analysis of the enhancement in cooling rates. In this paper an iterative numerical approach using DEFORM-3D and Ansys-Fluent has been discussed to understand the heat transfer phenomenon on textured tools. Results show that the heat transfer coefficient has increased by 32% with textured tool at moderate to high Reynolds number. The average cutting tool tip temperature dropped by 100°C due to tool-chip contact length reduction and increased heat dissipation. [ABSTRACT FROM AUTHOR]