Development of a 3D multiphysics model for the analysis of the thermo-mechanical effect of cooling lubricant in metal cutting

Cooling lubricants are used in machining processes to cool and lubricate the machining site as well as to carry away the chips. In addition to conventional flood cooling, high-pressure coolant supply showed its great potential to improve productivity when machining difficult to cut materials. To maximize the effectiveness of the high-pressure coolant system, the coolant must be directed to a suitable location with the correct pressure and flow rate. Until now, the design of the cooling system are mainly based on experimental experiences. Due to limitations of measurement technologies, the interaction between cooling lubricant jet and chip formation is not directly observable, so the high-pressure coolant system cannot exploit its full potential.

To cover the shortage of experimental methods, a 3D multiphysics model is being developed, with which the thermo-mechanical effect of cooling lubricant in machining can be determined. Previous research has shown that it is generally possible to simulate the flow behavior of the cooling lubricant with simultaneous consideration of chip formation. With the 3D multiphysics model, further physical effects of fluid and structural mechanics, as well as thermodynamics, can be qualitatively analyzed. Simulation results can be used to assist users in the design of process, tool and machine.