Date of Award

Fall 1995

Document Type

Thesis

Degree Name

Master of Science in Manufacturing Systems Engineering - (M.S.)

Department

Industrial and Manufacturing Engineering

First Advisor

George Hanna Abdou

Second Advisor

Layek Abdel-Malek

Third Advisor

Sanchoy K. Das

Abstract

Many cooling systems of metal cutting and both their advantages and disadvantages have been reviewed. The cutting forces' relationships, stress distribution, energy consumption and heat generation of orthogonal processes are discussed. A two-dimensional finite element model has been developed to design and analyze a new proposed cooling device, which comes from the idea of "A Novel Cooling Device" proposed by Billatos et al. First, a thermal calculation is completed to compare the temperature difference between two different shapes of coiled pipe. Then, three different cutting conditions, which were considered in the experiments by Childs et al, are conducted under three varying cooling environment: Dry Cutting, New Cooling Device, and Wet Cutting for case studies. The corresponding temperature distributions around the cutting edge have been obtained by using the ANSYS package. Results showed that the proposed new cooling device does reduce the temperature of cutting tool comparing with the Dry Cutting, but it increases the temperature and temperature boundary of cutting tool comparing with Wet Cutting. This makes the proposed cooling device to be suitable under some cutting conditions when: 1. it is necessary to eliminate the cutting fluids and; 2. the maximum temperature of tool by using the device is below the temperature of tool thermal failure.

Included in

Manufacturing Commons

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