Investigation of the cutting fluid’s flow and its thermomechanical effect on the cutting zone based on fluid–structure interaction (FSI) simulation

Abstract Cutting fluids are an important part of today’s metal cutting processes, especially when machining aerospace alloys. They offer the possibility to extend tool life and improve performance. However, equipment handling also raises manufacturing costs. To reduce negative impact high cost fluids, cooling systems strategies constantly being optimized. In most existing works, influences different on relevant process state variables, such as wear, forces, chip breakage, etc., empirically investigated. Due limitations experimental methods, analysis modeling working mechanism has so far only been carried out at a relatively abstract level. For better understanding thermal coupled two-dimensional simulation approach for orthogonal was developed in this work. This is based Coupled Eulerian Lagrangian (CEL) method provides detailed investigation fluid’s formation temperature. model validation, tests were conducted broaching machine. The resolved fluid behavior area showed distribution convective surface. work demonstrates potential CEL-based simulation, but pointed shortcomings method.