CFD Simulation of Fluid Flow and Heat Transfer of Internal Cooling Channels for Turning Tool

The internal-cooling approach emerged as an alternative in sustainable machining practices due to its multiple benefits. Cooling channels have been applied to cutting inserts to remove heat concentrated in a small area during machining. As a result, these cooling channels are critical in lowering tool temperatures and wear rates. The design of the cooling channel influences the effectiveness of heat management. In the present study, three types of cooling channel designs have been developed to investigate the cooling effect on the insert from the variety of cooling channel profiles. Computational Fluid Dynamics (CFD) is utilized to simulate the cooling effect for all profiles. A temperature reduction has been observed for the internally cooled cutting insert compared to the conventional tool without a cooling channel. The temperature difference is observed when the profile of the channel is varied. In addition, the coolant profile has been observed to be more effective in heat removal when the inlet pressure of the cutting fluid is increased. Through the velocity vector results, it has been determined that the heat transfer rate increases as the flow velocity of coolant within the channel increases. The Turbulence Kinetic Energy (TKE) simulation's value shows that a heat transfer rate enhancement is attained by elevating the TKE value, which depends on the configuration of the coolant flow channel.