Additive Solutions for Subtractive Problems in Cutting Tool - Next Generation Machining Processes for Advanced Alloys.

制造业是所有工业化国家的基础部门。然而，所使用的传统技术在社会、经济或环境能力方面已不再可行。该行业的主要分支之一是机械加工，并有两个最大的消耗品；切削工具，如钻头和切削液（喷在切削工具上的油、水和化学添加剂的混合物）。在使用时，切割工具会变得非常热，并受到高压。这会导致它们很快磨损，变得无法使用。为了延长刀具的使用寿命，切削液在加工过程中直接喷洒在刀具上，降低了刀具表面的温度并润滑了刀具表面。然而，切削液不环保，不可持续，有相关的健康风险，在某些应用中无法使用，例如核或医疗，并且占组件/产品总制造成本的15-20%。在过去的20年里，已经有了热稳定切削工具的替代尝试。对于非常小的固定工具，刀架中的散热器被用来间接冷却工具，流体通过工具内部循环的通道，并通过刀架返回。对于较大的旋转工具，这些方法是不可行的。为了降低一些旋转刀具的温度，切削液通过中心孔从刀架输送到刀具末端。然而，这种方法仍然需要使用有害的切削液。该项目的目的是降低切削刀具的温度，以追求更长的刀具寿命和去除切削液的要求。这将随后减少材料浪费和切削液的有害副作用。为了实现这一目标，将研究以下目标：1)增材制造方法。增材制造一层一层地构建三维物体，并使高度复杂的内部结构得以发展，否则在物理上是不可能的。这将允许内部冷却通道和流动路径的最佳设计。2)通过应用计算流体动力学和热分析找到最佳设计，3)研究旋转气缸的流动路径，4)应用优化算法，5)在专门开发的钻机上对增材制造的原型工具进行实验测试。

The manufacturing industry is a fundamental sector of all industrialised countries. However, the traditional techniques utilised are no longer viable in a social, economic or environmental capacity. One of the major branches of this industry is machining and has two of the largest consumables; cutting tools e.g. drill bits and cutting fluids (a mixture of oil, water and chemical additives that are sprayed at the cutting tool). When in use, cutting tools get very hot and are subjected to high pressures. This causes them to wear down very quickly and become unusable. To prolong the life of the tools, cutting fluids are sprayed directly at them during machining, reducing the temperature and lubricating the surface of the cutting tool. However, cutting fluids are not environmentally friendly, not sustainable, have associated health risks, are unusable in certain applications e.g. nuclear or medical and account for 15-20% of the total manufacturing cost of a component/ product. There have been alternative attempts to thermally stabilise cutting tools over the last 20 years. For very small, stationary tools, a radiator in the tool holder has been utilised to indirectly cool the tool and fluid has been passed through a channel that loops inside the tool and back out through the tool holder. These are not feasible methods for larger, rotating tools. In order to reduce the temperature of some rotating tools, cutting fluids have been delivered from the tool holder, to the end of the tool, through a central hole. However, this method still requires the use of harmful cutting fluids. The aim of this project is to reduce the temperature in cutting tools in pursuance of a longer tool life and removal of the cutting fluid requirement. This will subsequently reduce the amount of material waste and detrimental side effects of cutting fluids.In order to achieve this the following objectives will be investigated: 1) additive manufacturing methods. Additive manufacturing builds a three-dimensional object, layer by layer and enables the development of highly complex internal structures that would otherwise be physically impossible. This will allow for the optimum design of internal cooling channels and flow paths. 2) The optimum design will be found through the application of computational fluid dynamics and thermal analysis, 3) the investigation of flow paths in rotating cylinders, 4) application of optimisation algorithms and, 5) experimental testing of the additively manufactured prototype tools on a specially developed rig.