Journal of Manufacturing Processes 73 (2022) 164–176

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Journal of Manufacturing Processes

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CFD based study of fluid flow and heat transfer effect for novel turning tool
configured with internal cooling channel
Rohit Singh a, Varun Sharma b, *
a
Research Scholar, Additive & Subtractive Manufacturing Lab, Department of Mechanical and Industrial Engineering, IIT Roorkee, India
b
Department of Mechanical and Industrial Engineering, IIT Roorkee, India

A R T I C L E I N F O A B S T R A C T

Keywords: Internal-cooling method due to its numerous advantages has been used during the machining of hard to cut and
Internal-cooling difficult to machine materials. Cooling channels developed in the cutting inserts, drills, end mills and grinding
Heat generation wheels are used for the heat removal which is concentrated at a smaller region during machining process. So,
Turbulence Kinetic Energy (TKE)
these cooling channels play a vital role in decreasing the temperature and wear rate of the tools. The heat
Turning
Cutting inserts
generation and transfer rate depend upon the physical configuration of the cooling channel. This research work
presents novelty in the concept of developing internal cooling channel cutting inserts with different profiles.
Three different profiles have been developed to investigate cooling effect on the turning tool insert with different
shapes. The results have been compared with the standard tool having no cooling channel. Computational Fluid
Dynamics (CFD) has been used to simulate temperature rise for all profiles. A temperature drop of 188 K has been
found for internally cooled cutting insert in comparison to the standard tool having no channel. It has also been
found that the temperature difference of range 20 K–88 K can be achieved by varying the profile of the channel.
Besides this, an increase in the inlet pressure of the cutting fluid has been found to make the coolant profile more
efficient in terms of heat removal. Through the velocity vector results, it has been found that with more flow
velocity of coolant inside the channel more heat transfer takes place. Turbulence Kinetic Energy (TKE) results
showed that the heat transfer rate can be increased with an increase in the TKE value which in turn depends upon
the profile of the coolant flow channel. This CFD study in turn has laid the platform for setting the optimum
parameters during the turning of Titanium alloy with internal cooling channels.

1. Introduction
Machining is a material removal process to obtain the final product
of desired shape and size. This process uses different types of tools for
drilling, milling, grinding and turning processes. Material properties like
hardness, brittleness, ductility, thermal conductivity have a great impact
on the machining of materials. Some materials are very easy to cut but
some materials come under the category of difficult to cut materials like
Titanium alloys, nickel alloys etc. [1,2]. Titanium and nickel-based al­
loys are extensively used for aerospace industries, nuclear power plants
and medical industries [3] due to their good mechanical and metallur­
gical properties at an elevated temperature [2]. In spite of these ad­
vantages, stringent properties of both nickel and titanium alloys result in
their poor machinability.
During machining, the cutting tool removes material in the form of
chips through plastic deformation and shearing. This mechanical action
is then converted into heat [4]. The friction comes into action when tool
rubs against the workpiece during material removal process [5]. The
above mentioned phenomenon generates heat which leads to an in­
crease in the temperature at the tool-workpiece region. So, it is very
much important to analyse the heat generated during machining for
better tool life. In case of difficult to cut materials, like titanium and
nickel alloys due to their low thermal conductivity, heat does not flow
through workpiece and temperature rises upto 1373 K [6]. The tool life
is directly associated with this increase in temperature which also affects
the machining cost of the material. Many research attempts have been
made with an aim to decrease the temperature rise to add more life to
cutting tools along with the reduction in the machining cost. In an
attempt to increase the tool life, Rodríguez et al. [7] used liquefied CO2
during drilling of CFRP-Ti6Al4V and compared the results with dry
drilling. It was found that there occurs a substantial temperature
reduction with improved surface integrity and extended tool life with

* Corresponding author.
E-mail address: varun.sharma@me.iitr.ac.in (V. Sharma).

https://doi.org/10.1016/j.jmapro.2021.10.063
Received 3 September 2021; Received in revised form 21 October 2021; Accepted 25 October 2021
Available online 13 November 2021
1526-6125/© 2021 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
R. Singh and V. Sharma
Table 1
List of different important cooling methods with description.
Methods Description
Flood cooling method This technique is a traditional method to decrease the
temperature by supplying coolant with the help of a
pump to the cutting area. This method has negative
effect due to use of coolant in bulk which is dangerous
for environment (such as handling waste and used
coolant) and operator's health (can cause skin
problems) [8–10].
Dry cutting method This technique helps in decreasing environmental and
health issues. Due to absence of the coolant, it has
some limitations in speed while machining which in
turn affects productivity [11–14]
Minimum Quantity In this method, a very less amount of lubricant is
lubrication (MQL) supplied through the nozzle at cutting zone with high
pressure. It provides a very good effect in decreasing
the cutting temperature as the lubricant can reach
tool and workpiece and chip contact areas
[10,14–16].
Cryogenic method During cryogenic cooling (mostly liquid nitrogen) at
low temperature is directed with high pressure to
cutting region. Liquid nitrogen is not dangerous for
the health of operators and also it gets evaporate
leaving behind nothing as residuals. This method
maintains a very low machining temperature which
increases the tool life. It has some limitations as
constant supply of coolant is required and also ice
formation is there on tool and tool holder [10,17–21].
Solidlubrication method The use of graphite and molybdenum disulphide as
solid lubricants also helps in decreasing the cutting
temperature [19].
Internal cooling channel In this method, coolant or cryogenic working fluid is
flown through microchannel introduced under the
cutting tool insert. This method is useful in removing
heat close to the cutting zone. This in turn provides an
effective mean for lowering the machining
temperature [22].
the use of liquefied CO2 in drilling. Table 1 describes the various
methods for decreasing the cutting temperature during machining.
In a recent attempt, Pereira et al. [23] has performed cryogenic
assistance aided with external MQL lubrication while machining Inconel
Fig. 1. Line diagram with internal cooling channel tool.
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Journal of Manufacturing Processes 73 (2022) 164–176
718 and found the tool life improved by 57% as compared to MQL
lubrication method. Among all methods mentioned above, internal
cooling channel is the most innovative and promising method. Rozzi
et al. [24] studied the effectiveness of the cooling by flowing nitrogen as
coolant through microchannel beneath the insert. Sun et al. [25]
designed internally cooled turning tool and performed an experiment on
aluminium alloy. It was found that this method helped to attain a lower
turning temperature by 308 K. In another research attempt, Li et al. [26]
performed topology optimisation and CFD simulation for internal
cooling channel. A temperature drop of 453 K has been reported for
internal configured tool. The methods for the cooling used by above
mentioned researchers comes under category of indirect cooling method
in which coolant is not directed to cutting zone, rather the coolant cir­
culates through the channel. In this regard, Wu et al. [27] has designed
and developed an internal cooling turning tool with channel between
the cutting insert and the adapter. The result for the maximum tool
temperature has been verified by using Finite Element Modelling
(ANSYS and Fluent) with the experimental results.
Some work has been done for direct cooling methods in case of
turning and other machining processes. In this direction, Polvorosa et al.
[28] used a modified tool holder to perform face turning of alloy 718 and
Waspaloy. The authors used modified tool holder to supply high pres­
sure coolant (80 bar) at cutting zone and compared the results with
conventional cooling (6 bar). It has been found that high pressure
coolant lead to less flank wear in both the alloys. In another research
attempt of A. Suárez et al. [29] used high pressure jet during turning of
Inconel 718 to analyse the wear pattern, cutting forces and temperature
effect. Finite Element analysis has also been performed to see the notch
formation and compared the result with conventional flood cooling and
high pressure coolant technique. In continuation to earlier work A.
Suárez et al. [30] has used high pressure coolant technique in turning of
one of the novel difficult to cut materials i.e. Haynes 282 and optimized
the cutting parameters. Naves et al. [31] compared the flank wear re­
sults for flood and dry cooling with internally cooling channel method.
Peng et al. [32] tested cutting temperature and surface finish for
grinding process by developing internal slot in the grinding wheel. O.
Pereira et al. [33] used hybrid Cryo MQL techniques with CO2 flow
through the internal channel during milling process. The results showed
R. Singh and V. Sharma Journal of Manufacturing Processes 73 (2022) 164–176

Fig. 2. CAD model of cutting insert.

Fig. 3. Coolant flow channel profiles a) profile 1 b) profile 2 c) profile 3.

Table 2
Listed properties for the cutting insert and the coolant.
Materials Thermal conductivity W/ Thermal expansion Atmospheric heat capacity J/ Density kg/ Modulus of elasticity Poisson Viscosity (kg/
(m⋅K) 1/K (kg⋅K) m3 GPa ratio m s)
6
Tungsten 69 6 × 10− 180 15,770 710 0.24 –
carbide
Water 0.6 – 4182 1000 – – 0.001

that there occurs a decrement of 10% in cutting forces on using the in­ flow through the internal cooling channel using CFD. In this regard,
ternal channel and also the consumption for the CO2 gas was found to Oezkaya et al. [34] numerically verified the results for the internally
reduce as compared to other approaches like only Cryo-MQL and MQL. cooled drilling process with the experimentation. R. Peng et al. [22]
Some research attempts have also been made to evaluate the coolant performed an experiment on turning of Inconel 718 alloy with newly

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From the above literature, it can be inferred that heat transfer during
machining depends upon the velocity of coolant flow through the
channels. Besides the coolant, flow profile is the main factor that pro­
motes heat convection during the coolant flow. So, there is great scope in
developing a profile of the internal channels to optimize the results
during the machining. In this paper, an attempt has been made to
simulate temperature rise during machining of Ti6Al4V with internal
cooled cutting insert. In the first phase, temperature distribution during
dry turning of alloy with carbide tool has been predicted and validated
with experimental work of Khan et al. [38]. In the second phase under
similar conditions, the temperature distribution at cutting insert with
the internal cooling channel has been simulated. The CFD simulation is
used to investigate heat transfer effect through different designed pro­
files in cutting inserts. ANSYS and Fluent 19.0 software have been used
for investigating the results. During the simulation process, heat transfer
capacity, velocity for the coolant through the channels and outlet
pressure has been considered for the optimum profile selection.

2. Materials and methods

Fig. 4. Convergence test results for average velocity values by varying the
2.1.1. Working principle
elemental size.
During the machining of Ti based alloys, the heat generated at the tip
of the tool remains concentrated due to poor thermal conductivity of
developed internal cooling channel microstructure and confirmed the
work material. This heat is not able to flow through the workpiece thus
results with CFD simulation. Fang et al. [35] used CFD simulation to
temperature rises in localised regions. However, the temperature rise
investigate the flow of cutting fluid with compressed air during the
can be lowered using various cooling methods. During dry cutting, only
turning process. CFD simulation was used to visualize the turbulent flow
mode of heat flow is conduction through the insert and workpiece. While
and heat transfer effect through the channels. Through the CFD simu­
using flood cooling method heat is lost due to flow of the coolant
lation, Lacalle et al. [36] showed the effect addition of biodegradable oil
through the tool-workpiece contact area. In case of internal cooling
through spraying on the tool flank wear and also verified it through the
channel, heat is taken away by the flow of coolant through the channel
experimental work. CFD approach was also made by Pereira et al. [37]
developed inside inserts. As the channel passage is close to the heat
during the designing of novel nozzle for combining cryogenic with MQL
concentrated zone, the use of pressurized coolant takes away heat in an
techniques of cooling. The developed nozzles have been used to compare
efficient manner. Fig. 1 shows the heat interaction among workpiece,
the CFD results with experimental data. It has been found that the CFD
tool and coolant during machining with internal cooling channel tool.
simulation is the best tool to investigate the coolant flow, mechanical
The heat flow also depends upon the internal channel structure, inlet
strength, deformation and heat transfer effect during the machining
velocity and pressure of the fluid. On increasing the fluid inlet velocity,
process by using the internal cooling method.

Fig. 5. Temperature contour for the tool without profile.

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R. Singh and V. Sharma Journal of Manufacturing Processes 73 (2022) 164–176

Fig. 6. Experimental and simulation result of maximum cutting temperature for standard and internally cooled tool- tip.

the pressure cooling efficiency increases to a certain limit. After that, [ ]

higher velocity of fluid results in very little time for heat exchange be­ ∂(ρu) ∂(ρu) ∂(ρu) ∂(ρu) ∂2 u ∂2 u ∂2 u ∂P
+u +v +w = Fx + μ[ 2 2 + 2 2 + 2 2] − (4a)
tween fluid and insert [26]. So, there will be an optimized pressure and ∂(∂ρtv)
+u
∂(∂ρxv)
+v
∂(∂ρyv)
+w
∂(ρ∂zv) ∂∂xv ∂∂yv ∂∂vz
= Fy + μ [ 2 2+ 2 + − ]
∂P
∂x
(4b)
velocity of the fluid for a particular type of designed channel. ∂(∂ρtw) ∂∂(ρx w) ∂∂(yρw) ∂z(ρw) ∂x∂ w∂y ∂2 w∂z2 ∂2 w ∂y ∂P
+u +v +w = Fz + μ + + −
∂t ∂x ∂y ∂z ∂x2 ∂y2 ∂z2 ∂z
2.1.2. Cooling/Heat transfer (4c)
The cooling effect through the channels can be explained through the Besides this, the energy balance equation used in CFD is given by Eq.
governing equations in the following sections. The energy balance (5) [26]:
equation for heat in conduction mode i.e. tool without cooling channel is
[ ] [ 2 ]
given by Eq. (1) [26]: ∂T ∂T ∂T ∂ T ∂2 T ∂2 T
ρ∁ u + v + w =γ + + (5)
∂x ∂y ∂z ∂x2 ∂y2 ∂z2
∂2 T ∂2 T ∂2 T ρ∁ ∂T
+ + = (1)
∂x2 ∂y2 ∂z2 k ∂t In the above equation ∁ is heat capacity for the fluid, ρ represents
density for the fluid, u, v, w are the fluid velocities in x, y and z di­
where k represents thermal conductivity coefficient, ρ represents den­ rections, Fx, Fy, Fz are the forces acting on the fluid in x, y and z di­
sity,∁ is heat capacity and t denotes time. rections, μ is viscosity of fluid and γ is thermal conductivity of the fluid.
But, in case of cooling system, having internal cooling channel with It can be seen from above equations that cooling channel efficiency
coolant passing through the channel convection mode of heat transfer is depends upon the properties of the fluid like μ, ρ and ∁ etc. and the
the major contributing factor. The governing equation which represents geometrical dimension of the channel.
heat absorbed during flow of coolant is given by Eq. (2) [26]:
2.1.3. Simulation procedure
Q = Ai ∁p ρp Vi (To − Ti ) (2)
Due to low chemical affinity properties of workpiece towards tung­
sten carbide, it has been an extensively used material for tool fabrica­
where Ai is area for inlet cooling channel, ∁p is heat capacity, ρp mass
tion. So, in this paper uncoated tungsten carbide cutting insert has been
density for the fluid, Vi is velocity coolant flow, To and Ti represents
selected for the model development. The CAD model for the cutting
outlet and inlet temperature for the coolant respectively.
insert with dimensions as per CNMG160612 is shown in Fig. 2.
The CFD approach follows the mass, momentum and energy con­
In the next step, different cooling channel profiles have been
servation equation to simulate the problem. The mass conserving
generated inside the insert with equal material removal. The inlet area
equation is also known as continuity equation can be expressed as Eq.
diameter for channels has been kept constant for all the profiles. The
(3) [26]:
different profiles of the cooling channels are shown in Fig. 3. The inlet
∂ρ ∂(ρu) ∂(ρv) ∂(ρw) and outlet for the channel are marked with (I) and (O) respectively.
+ + + =0 (3)
∂t ∂x ∂y ∂z These CAD models are then imported to ANSYS further CFD simu­
lations. A uniform constant heat flux 63 W/mm2 has been generated at
Newton's second law of motion is the base for the momentum
the tip of the tool to simulate the temperature encountered during
equation in CFD. These are also known as the Navier-Stokes equations
machining. During simulation, it has been assumed that the thermal
and it is expressed as Eqs. (4a), (4b), (4c) in x, y and z directions
conductivity of the insert is constant and does not vary with respect to
respectively [26,39].
temperature. Water has been selected as the coolant fluid at room
temperature [26]. The properties of the material used during CFD

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R. Singh and V. Sharma
Fig. 7. Maximum stress generation for a) Tool without cooling channel b) Profile 1 c) Profile 2 d) Profile 3.
simulation is mentioned in Table 2.
2.1.4. CFD modelling and boundary conditions
In order to develop realistic simulation following boundary condi­
tions have been adopted in the present research attempt during the CFD
simulation. The fluid solid model has been meshed using proximity and
curvature method. The minimum elemental size has been kept as 0.1
mm and the total number of an element is 3,426,925, 3,410,802 and
3,402,735 in the case of profiles 1, 2 and 3 respectively. This method has
been used as it takes into account the curvature and proximity region of
the model while meshing. The fluid-solid interface in the model has been
further refined and inflation layer with a first layer thickness of 0.01 mm
and growth rate of 1.2 has been generated to achieve the best results for
accurate calculation. In order to simulate the flow through the channel
following boundary conditions has been applied. At the inlet of the
cooling channel (I) boundary condition is taken as pressure inlet. This
boundary condition satisfies the actual condition as with the external
pressurized system inlet pressure for the fluid can be varied. At outlet
(O) atmospheric pressure has been set as boundary condition. During the
simulation, considering turbulence model standard k-ε model has been
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Journal of Manufacturing Processes 73 (2022) 164–176
used to enhance wall treatment [35]. The fluid-solid interface has been
considered as a coupled system so that heat can transfer in a good
manner. The other regions have been selected as system coupling
boundary conditions for the transfer of heat in the insert itself through
conduction mode. The solution has been converged with the residual
value for 1. e− 06. The convergence test result for facet average velocity
by varying the elemental size has been shown in Fig. 4.
3. Discussion and results
3.1. Experimental and simulation validation
In their experimental work, Khan et al. [38] used Ti6Al4V material as
workpiece and performed turning with carbide cutting tool and
compared the results for forces and cutting temperature for dry and high
pressure coolant techniques. The cutting force has been measured dur­
ing the experimental work and is found to be a minimum of 706 N and a
maximum of 775 N at various speeds in case of dry cutting. The mini­
mum and maximum cutting temperature has been measured during dry
cutting is 710 ◦ C and 890 ◦ C respectively. During temperature
R. Singh and V. Sharma
Fig. 8. Deformation analysis for a) Tool without cooling channel b) Profile 1 c) Profile 2 d) Profile 3.
simulation for the dry cutting the maximum cutting temperature at the
tool tip has been found to be 1031 K (758 ◦ C) approximately. The
simulation result for the maximum temperature rise is in the range of
experimental data [38]. The lower value for maximum temperature
during the simulation can be accounted due to meshing criteria and
physical conditions during machining. However, the result for the
maximum temperature rise during dry cutting has been found to be
comparable with an experimental result. The temperature distribution
for the standard tool i.e. without cooling channel is shown in Fig. 5.
Similar conditions have been used to investigate the maximum
temperature rise for inserts having internal cooling channels with
various profiles as per Fig. 3. Fig. 6 shows the comparative results for the
maximum temperature rise in case of experimental dry cutting, simu­
lated dry cutting and temperature for cutting inserts with various pro­
files. However, the effect of coolant pressure through the channels on
the cutting temperature has been investigated further in the upcoming
sections.
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Journal of Manufacturing Processes 73 (2022) 164–176
3.2. Mechanical behaviour
The mechanical behaviour of the tools with cooling channel has been
compared with simple tool through structure analysis in ANSYS soft­
ware. The main cutting force of 706 N [38] [29] has been applied to tool
– chip surface area at the tip of the tool, the force equivalent to the main
cutting force during turning of Ti-alloy. Fig. 7 shows the results for the
total stress developed for the various cases. It is found that maximum
stress generated at tip of the tool is 1161 MPa for insert having no in­
ternal cooling channel.
The maximum values of stress generated in three cooling profiles 1,
2, 3 are 1206 MPa, 1174 MPa and 1204 MPa respectively. The stress
developed in the tool for all three profile cases is much lower than the
yield strength of the tungsten carbide. The results for the total defor­
mation are shown in Fig. 8.
It can be seen that the deformation of the tool is in the range of 2.8
μm–3.34 μm. Through the mechanical structure analysis, it can be
inferred that there is an increment of stress by 3.8% in case of profile 1,
R. Singh and V. Sharma
0.2
MPa
(a)
a): Temperature contour 1) for 0.2 MPa - a) Profile 1 b) Profile 2 c) profile 3
Fig. 9. a): Temperature contour 1) for 0.2 MPa - a) Profile 1 b) Profile 2 c) profile 3 b): Temperature contour for 1 MPa - a) Profile 1 b) Profile 2 c) profile 3.
1.1% for profile 2 and 3.7% for profile 3 compared to the stress value of
standard tool. Thus, it can be deduced that the profile generation results
in negligible changes in the mechanical strength of the cutting inserts.
Therefore, the CFD simulations can be easily performed without
compromising the strength.
3.3. Structural/Shape effect on the rise of temperature
The temperature distribution for the standard tool i.e. without
cooling channel has shown above (Fig. 5). The localised region at the tip
of the tool has a maximum temperature of 1031 K and rest portion is at
room temperature. Under similar physical conditions for all channels
from Fig. 9(a and b), it can be seen that at lowest inlet pressure of 0.2
MPa the maximum temperature rise during the simulation is 931 K, for
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Journal of Manufacturing Processes 73 (2022) 164–176
(b)
(c)
profile 2. The temperature rise for profile 1 is 911 K and considering
same input it can be seen that the lowest temperature is achieved by
profile 3 i.e. 843 K. The coolant inlet pressure variation is found to lead
to a decrease in the temperature of tool. The maximum drop of 8 K from
911 K to 903 K has been found during the simulation for profile 1 by an
increase in the inlet pressure from 0.2 MPa to 1 MPa. Similarly, the
temperature drop in the case of profile 2 and 3 on a variation of inlet
pressure is 6 K and 5 K respectively. Fig. 9 depicts the temperature
distribution for the cutting insert with different cooling profiles at 1 MPa
inlet pressure.
It can also be seen that tool temperature gradually decreases as move
away from the tip. This is in line with the findings of R. Peng et al. [22].
The maximum temperature rise during machining and drop of temper­
ature due to variation of inlet pressure depends upon the shape of the
R. Singh and V. Sharma
1 MPa
(a)
b): Temperature contour for 1 MPa - a) Profile 1 b) Profile 2 c) profile 3.
Fig. 9. (continued).
coolant channel. It can be inferred that larger the portion of coolant
covers the heated insert more will be the drop in temperature. The tool
configured as per profiles 1 and 3 design has curve shape. The coolant
flowing through profiles 1 and 3 covers a larger portion of the tool and
thus absorb more heat which leads to lower temperature rise as
compared to profile 2.
By making the coolant flow closer to the tip of the tool, the tem­
perature rise in the insert can be lowered. The design of profiles 1 and 3
have similar characteristics due to curvy nature towards tip of the tool
coolant is forced to move closer to the heated region thus absorbing
more heat. Besides this maximum temperature is concentrated at tip of
the tool, thus flow of the coolant closer to the tip will result in lower
temperature. This is in line with the findings of Li et al. [26].
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Journal of Manufacturing Processes 73 (2022) 164–176
(b)
(c)
3.4. Inlet pressure and inflow velocity effect on temperature rise
In order to study the effect of inlet coolant pressure on the temper­
ature rise during the turning process, different values corresponding to
the pressure has been considered. i.e. 0.2 MPa, 0.3 MPa, 0.5 MPa, 1 MPa
until temperature rise becomes constant. Simulations have been done
for all the developed profiles making other physical conditions like inlet
coolant temperature constant. It can be seen that a rise in the inlet
pressure of the coolant results in a decrease in the temperature. How­
ever, it is not following any particular linear relation. As channel designs
have some corners and chamfers, which can lead to turbulence phe­
nomenon it has been neglected during simulation due to very small area
for corners in channel and high velocity of the fluid. The overall Tur­
bulent Kinetic Energy effects on the heat transfer rate for the channels
have been considered in the following sections. Fig. 10 shows the
R. Singh and V. Sharma
Fig. 10. Variation of temperature with pressure for different profiles.
temperature rise with inlet pressure variations for all profiles.
It can be further noticed that during simulation the temperature drop
becomes constant with an increase in the pressure. This behaviour can
be accounted for the fact that as the pressure increases, the inflow ve­
locity of the coolant in channel increases. This results in less time for the
coolant to absorb the heat and thus convective heat transfer does not
take place. This result is in line with work of Li et al. [26] that for every
profile there is some optimised pressure and velocity after which there
will be no significant changes in the temperature drop.
The variation in the temperature difference among the profiles can
be easily understood by the fact that as the coolant flows through the
channel, the heat is transferred through the forced convection method.
Fig. 11. Velocity contour for the different profiles through a channel for 0.2 MPa and 1 MPa pressure.
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Journal of Manufacturing Processes 73 (2022) 164–176
The heat transfer rate (Q) is directly proportional to heat convective
coefficient as shown in equation [22]:
Q = Ac h(Tt − Tc ) (6)
where h is heat transfer coefficient, Tt and Tc are the tool and coolant
temperature and Ac coolant channel area.
As during simulation, a constant heat flux has been considered so the
Nusselt number relation can be expressed as shown in Eq. (7) in terms of
Reynolds and Prandtl number [22]:
hl
Nu = 0.453R0.5 0.3
e Pr = (7)
k
where Re is Reynolds number and it is represented as ρμvl and Pr is Prandtl
number which is given by ckμ, ρ is density, k is heat conductivity, v is
inflow velocity, μ and c are viscosity and specific heat capacity. It can be
seen that Reynolds number is directly proportional to the inflow ve­
locity. Thus, Nusselt number (Nu) is has a direct relation with Reynolds
number and heat transfer coefficient. Thus, rise in the flow velocity
results in a higher Reynolds number which leads to the higher value of
Nusselt number. Eq. (7) also relates heat convective coefficient with
Nusselt number in direct proportional relation. The high value of h will
increase the heat transfer rate Q thus, leading to the maximum tem­
perature drop.
Therefore, maximum inflow velocity will result in a maximum drop
of temperature during the turning process. Through the simulation re­
sults, it can be seen that maximum velocity is attained for profile1 as
compared to others. Fig. 11 show the velocity contour of fluid for the
different profiles by varying the pressure.
It can be seen that a maximum velocity of 11.6 m/s is achieved in
case of profile 1 at 1 MPa. Hence, the temperature drop is found
maximum in profile 1 on pressure variation as this profile gains
maximum flow velocity of the fluid. Fig. 12 shows the velocity vector for
the three profiles. Velocity vector represents magnitude and direction of
the fluid velocity in a particular domain. These vectors are drawn at the
R. Singh and V. Sharma
Fig. 12. Velocity vector 1) at 0.2 Mpa a) Profile 1 b) Profile 2 c) profile 3 2) at 1 MPa - a) Profile 1 b) Profile 2 c) profile 3.
Fig. 13. Temperature vs. velocity plot.
centre of each facet. Due to shape, variation of the channels some
portion of the profile boundaries does not come in contact with the
coolant thus heat transfer effect decrease in these cases, while profile 3
has a full flow of the fluid in its passage.
3.5. Effect of Turbulence Kinetic Energy on heat transfer rate
Besides the structure of profile and inflow, velocity of the coolant
another important factor which promotes the heat transfer rate is Tur­
bulence Kinetic Energy (TKE). TKE is specific kinetic energy which is
generated inside the channel due to flow velocity of the fluid or coolant.
Inlet pressure variation of the fluid leads to variation in fluid flow ve­
locity through channels. During simulation, it has been observed that
TKE also varies with inlet fluid pressure variation. The heat transfer
quality can be enhanced by generating turbulence in the flow. The
methods such as fins addition, groove formation and changing the flow
pattern are being used to increase turbulence in flow [40,41]. By
considering this principle, it has been found that by developing different
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Journal of Manufacturing Processes 73 (2022) 164–176
profiles shape flow patterns can be varied. Profile 1 has more TKE value
compared to the other two profiles, so temperature drop in profile 1 is
found to be a maximum in comparison to other profiles. It has been
observed that TKE can increase the rate of heat transfer. This works in
line with the findings of Z. Fang et al. [35]. Fig. 13 shows the temper­
ature vs. inflow velocity graph for all three cases.
Fig. 14 shows the value of TKE at different pressures for all three
profiles. It can be seen that values in all three cases increase with
pressure variation. Besides this, a higher change in TKE values results in
a maximum drop of temperature with respect to pressure.
4. Conclusions
This study shows the effect of profile configuration through the CFD
simulation. The following conclusions can be drawn:
• Under similar physical conditions, maximum and minimum limit of
stress variation in tool with cooling channels is 3.8% and 1.1% in
case of profile 1 and 2 respectively in comparison with stress
generated in standard tool.
• The provision of internal cooling channel increases the cooling effect
by decreasing the temperature. There is maximum temperature drop
of 188 K in tool with channels and standard tool.
• A variation of the profile structure leads to temperature difference of
88 K among the profiles under consideration.
• The heat transfer rate for the fluid can be enhanced by TKE factor
which depends upon the profile structure.
In the current study CFD analysis for the optimum cooling effect due
to generation of internal channel during the turning of Ti- alloy has been
performed. In future, on the basis of above results cutting inserts with
the best configured channel will be fabricated through sintering process
and results will be compared with CFD and experimental work.
Declaration of competing interest
The authors declare that they have no known competing financial
interests or personal relationships that could have appeared to influence
the work reported in this paper.
R. Singh and V. Sharma
Fig. 14. TKE vs. Pressure for profiles.
Acknowledgements
The authors would like to thank ARDB, DRDO project no. DRD-1434-
MID for funding this project.
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