Md Ibthisum Alam
Analysing the influence of the workpiece geometry on the coolant flow field distribution during the milling process with internal coolant supply.
Rel. Daniele Ugues, Milena Salvo. Politecnico di Torino, Corso di laurea magistrale in Ingegneria Dei Materiali Per L'Industria 4.0, 2025
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Abstract
In the context of sustainable manufacturing, an efficient coolant delivery system is essential to minimize tool wear while maintaining the machined surface quality. The cooling performance, however, strongly varies depending on operating parameters and tool-workpiece interaction. The current study addressed this issue and developed a Computational Fluid Dynamics (CFD) model to evaluate coolant flow behavior in internally cooled milling. The simulations from the model were tested against surrogated experimental rigs, and the comparison showed good agreement. The analysis was based on the Design of Experiments (DOE) framework, particularly Central Composite Design (CCD), where the influence of three factors, namely workpiece geometry (flat vs.
curved), rotational speed (250–750 RPM) and coolant flow rate (20 30 l/min), on four performance metrics such as average coolant velocity, coolant volume fraction, coolant coverage area, and turbulence kinetic energy (TKE) were investigated
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