Development of a 3D multiphysics model to analyse the thermo-mechanical effect of coolants in metal cutting

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Coolants are still indispensable in many cases to realize safe and economical machining processes. Prior research focused on empirical studies regarding this topic and mainly investigated the effects of different coolant strategies on tool wear, forces, chip breakage etc. Analyses based on simulation models were limited to basic and simplified cases. Therefore the objective of this project is to develop a 3D multiphysics model to analyze the thermal and mechanical effects of the coolant used in metal cutting. In this context a model which simulates the formation of chips will be directly coupled with a model that simulates the thermal and mechanical behavior of the coolant jet. This approach enables the user to directly analyze the interdependencies between the chip formation and coolant jet. Especially when high pressures and flow rates are used in cutting of difficult-to-cut materials, such a model delivers valuable information for an effective and efficient design of process, tool and coolant supply.