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WO2021221586A1 - Smart cutter tool module for cnc lathes - Google Patents

Smart cutter tool module for cnc lathes Download PDF

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Publication number
WO2021221586A1
WO2021221586A1 PCT/TR2021/050387 TR2021050387W WO2021221586A1 WO 2021221586 A1 WO2021221586 A1 WO 2021221586A1 TR 2021050387 W TR2021050387 W TR 2021050387W WO 2021221586 A1 WO2021221586 A1 WO 2021221586A1
Authority
WO
WIPO (PCT)
Prior art keywords
temperature
microprocessor
cutter tool
fluid
tool tip
Prior art date
Application number
PCT/TR2021/050387
Other languages
French (fr)
Inventor
Erkan Ozturk
Kemal YILDIZLI
Original Assignee
Ondokuz Mayis Universitesi
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ondokuz Mayis Universitesi filed Critical Ondokuz Mayis Universitesi
Priority to DE112021002569.4T priority Critical patent/DE112021002569T5/en
Publication of WO2021221586A1 publication Critical patent/WO2021221586A1/en

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23QDETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q11/00Accessories fitted to machine tools for keeping tools or parts of the machine in good working condition or for cooling work; Safety devices specially combined with or arranged in, or specially adapted for use in connection with, machine tools
    • B23Q11/14Methods or arrangements for maintaining a constant temperature in parts of machine tools
    • B23Q11/141Methods or arrangements for maintaining a constant temperature in parts of machine tools using a closed fluid circuit for cooling or heating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23BTURNING; BORING
    • B23B25/00Accessories or auxiliary equipment for turning-machines
    • B23B25/06Measuring, gauging, or adjusting equipment on turning-machines for setting-on, feeding, controlling, or monitoring the cutting tools or work
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23BTURNING; BORING
    • B23B27/00Tools for turning or boring machines; Tools of a similar kind in general; Accessories therefor
    • B23B27/10Cutting tools with special provision for cooling
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23QDETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q17/00Arrangements for observing, indicating or measuring on machine tools
    • B23Q17/09Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool
    • B23Q17/0952Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining
    • B23Q17/0985Arrangements for observing, indicating or measuring on machine tools for indicating or measuring cutting pressure or for determining cutting-tool condition, e.g. cutting ability, load on tool during machining by measuring temperature

Definitions

  • the present invention relates to an internal cooling smart cutter tool module for cooling the cutter tool tip during a turning process.
  • the present invention particularly relates to a smart cutter tool module comprising a smart control-cooler unit that is capable of controlling and determining the flow rate/speed and temperature of the coolant transferred to the cutter tool according to the extreme temperature values that it estimates based on the operating strategy thereof.
  • the turning method is one of the most commonly used methods of machining.
  • the turning process is the process of chip removal and shaping with a cutter tool that can move in different directions over a circular moving workpiece. While the workpiece performs the main movement by rotation, providing cutting depth and further movement is performed with the cutter tool.
  • Lathes that perform turning processes are also called turning lathes. Generally, cylindrical and conical surfaces are processed in the external inner sections with axial movement during turning.
  • lathes are used for the turning process. Some of these lathes are as follows; universal lathe, vertical lathe, revolver lathe, air-diameter lathe, copy lathe, bench type lathe, and CNC-mass production lathe.
  • CNC lathes unlike conventional lathes, are the lathes that produce workpieces serially in a short time with the determined measurement, progress, and revolutions by means of the ball screw and servo motor that move the axes with NC programs sent to a computerized control unit.
  • Thermal changes that occur at the sides of the cutter tool tips during the turning process cause wear, thermal erosion, measurement errors, an increase in surface roughness, and a decrease in tool tip life.
  • the heat generated in the cutting zone during chip removal causes negative effects on the workpiece surface.
  • the heat released during turning is a much more critical parameter for machinability particularly in materials actively used in industry such as nickel-based superalloys, titanium, composites, and high chromium white cast iron, which are difficult to process. High temperatures are observed and thus damage to the cutter tool tip is seen since these materials are difficult to process. Therefore, many studies in the state of the art have mentioned the importance of lowering the temperature in the cutting zone and extension of tool life with the decrease in the temperature, decrease in wearing of the tool tip, and the increase in quality of the machined surface.
  • a cutter tool is disclosed.
  • a base is designed so as to pass the liquid through it to the cutter tool used for turning.
  • the base consists of a liquid inlet, outlet, and channels in which the liquid cycles. It is assembled in two parts.
  • the liquid cyclotron is rotated in the channel within the base and the base is cooled.
  • the base is cooled since it is in contact with the cutter tool tip.
  • a cutter tool used for threading the outer surface in the lathe is disclosed.
  • the invention comprises of a cutter tool tip consisting of triangular grooves and a channel through which coolant is transferred to the tip to cool the tip.
  • water cycle channels with different geometries are used so as to cool the cutter tool tip when the cooling systems in the state of the art are examined in general.
  • a self-cooling tool is designed and produced so as to be able to process with a diamond-coated tip in a study carried out in the state of the art.
  • the tool tip is adapted to a block by opening a channel with micro-machining from a location close to the cutting zone. Cooling is ensured by passing coolant through this channel.
  • the temperature at the tool tip is measured with a pyrometer.
  • it is aimed to develop a self-cooling smart cutter tool for turning process in dry conditions.
  • an adapter is formed with a part that can be mounted under the cutter tool tip so as to cycle coolant through the cutter tool.
  • a micro-channel is opened under the cutting tool tip for adapting a base and the fluid is cycled through this channel. These channels are positioned as close as possible to the tool tip.
  • the temperature at the cutting tip is measured by means of thermocouples. While this fluid temperature is measured by means of the thermocouples, the coolant is cycled at a constant flow and a constant temperature by means of the pump through the microchannels. It can measure the inlet and outlet temperatures of the coolant. The optimum values are determined for different inlet temperatures and speeds that are manually adjustable.
  • a closed-cycle cooling system has been integrated into the cutter tool.
  • the cutting tip is cooled by passing the fluid taken from the cooling system through the channel opened to the tool holder in a spiral manner.
  • V-shaped channel was opened in the tool catheter and ensured cooling by cycling the fluid through the same. Furthermore, the temperature change between the tip and the chips is also monitored with a thermal camera.
  • Ttip temperature is determined according to the inlet and outlet temperatures of the coolant. There are still many parameters that affect Ttip values. These parameters are like the type and speed of the coolant, thermal properties of the cutter tool, and environmental conditions. Therefore, determining Ttip values only by correlation is not a sufficient approach.
  • the most important object of the present invention is to ensure that the invention comprises an internal cooling smart cutter tool module aimed at cooling the cutter tool tip during the turning process.
  • Another important object of the present invention is to estimate the temperature formed at the cutter tool tip by measuring the side surface temperature of the cutter tool tip, the inlet temperature, and the inlet flow rate of the coolant circulating in the closed cycle system.
  • the smart control-cooling unit has the ability to control and decide the flow rate/speed and temperature of the coolant sent into the cutter tool according to the extreme temperature values that it estimates according to its own operating strategy.
  • Yet another object of the present invention is to ensure that it has no negative effects on the health of the operator and to be environmentally friendly.
  • Another object of the present invention is to ensure that it has a modular structure that can either be used on traditional lathes or mounted as a further module on CNC lathes.
  • Another object of the present invention is to ensure that the system has its own working and calibration strategy and allows the operator to determine the operating temperatures. Therefore, it ensures that the cutter tool tip is kept within the specified temperature range during machining.
  • Another object of the present invention is to provide a base with specific geometry for the cutter tool tip. Therefore, the base directly contacts the fluid with the cutter tool tip, thus makes the cooling more efficient.
  • Another object of the present invention is to enable the use of any type of coolant.
  • Another object of the present invention is to ensure that it has its own calibration method based on CFD statistics.
  • tool tip temperature estimations can be customized according to coolant and cutter tool types and the accuracy of the estimation can be increased.
  • Another object of the present invention is to ensure that it has a microprocessor that runs software that can enter commands. Thus, it can keep the cutter tool tip temperature constant in the temperature range determined by the operator under certain cutting conditions.
  • Another object of the present invention is to ensure that it can be adapted to any type of standard cutter tool tip with its base design located on the cutter tool tip.
  • FIGURE-1 illustrates the general view of the inventive system.
  • FIGURE-2 illustrates the view of the inventive cutter tip of the smart cutter tool module.
  • FIGURE-3 illustrates the workflow view of the estimation method of the inventive module.
  • the present invention relates to an internal cooling smart cutter tool module for cooling the cutter tool tip (121) during the turning process.
  • the module can either be used on traditional lathes or mounted as a further module on CNC lathes.
  • This module can estimate the temperature (Ttip) formed at the cutter tool tip (121) by measuring the side surface temperature (Tf) of the cutter tool tip (121), the inlet temperature (Tinlet), and the inlet flow rate (Vf) of the coolant circulating in the closed cycle system.
  • the inventive module comprises a microprocessor (110) having a calibration approach based on CFD-statistics (Computational Fluid Dynamics, Calculated fluid dynamics) and its own operating strategy by cooling the cutting tool (120) cutting edges.
  • CFD-statistics Computational Fluid Dynamics, Calculated fluid dynamics
  • the coolant directly contacts the cutter tool (120) so as to effectively cool the cutter tool tip (121 ). For this reason, there is a fluid inlet (123) with an inclined surface for spraying coolant towards the chip contact area of the cutter tool tip (121) and the fluid outlet (124) that discharges the coolant on the cutting tool base (122).
  • the coolant cycled in the system is required to contact the cutter tool tip (121 ) as much as possible. Therefore the volume of the fluid tank (108) where the fluid cooling the system is stored is designed as large as possible.
  • the tool base (122) of the cutter tool (120) shown in Figure-2 is manufactured from stainless steel in dimensions suitable for the tool tip (121 ). Sealing between the tool tip (121) and the tool base (122) is provided by a gasket in the form of a thin film.
  • thermocouple 101
  • thermocouple sensor 102
  • LCD Screen 103
  • power source 104
  • pump driver 105
  • flow meter 106
  • pump 107
  • fluid tank 108
  • cooler unit 109
  • microprocessor 1-10
  • cutter tool 120
  • the cooling-control system of the inventive module switches on and off the module at the critical temperature values determined by the operator and transmitted to the microprocessor (110).
  • the microprocessor (110) of the module is capable of controlling the speed of the coolant sent into the tool base (122). In other words, when the temperature of the tool tip (121) increases, the coolant must be cycled faster in the module. Thus, there will be more efficient heat transfer.
  • the system has been designed and produced in two parts. Firstly, it receives feedback from the speed (Vf) of the coolant, its temperature (Tinlet), and the tool tip (121 ) side surface temperature (Tf) values and determines the cooling strategy. The other part of the module is responsible for cooling the coolant.
  • the operating scheme of the entire system is shown in figure-1 .
  • the cooling-control system has three main services. These services are controlled by the microprocessor (110). Vf, Tinlet, and Tf values received by the flow meter (106) and thermocouple sensor (102) are transmitted to the microprocessor (110) and the microprocessor (110) is enabled to estimate the tool tip (121) temperature (Ttip). Furthermore, the microprocessor (110) enables the cooling system to operate when critically extreme temperatures are observed.
  • the microprocessor (110) operates the pumps (107) with the PID control and ensures that fluid is sent to the cutter tool base (122) at different speeds in accordance with the increase in the Ttip value. The entire system is fed with a 12 V power supply (104) and all electronic parts are in contact with the microprocessor (110).
  • the microprocessor (110) directly interacts with K- type thermocouples (101 ), thermocouple sensors (102), LCD screen (103), DC pump drivers (105), flow meter (106), and cooler unit (109) and receives feedback from each of them.
  • thermocouples (101 ) that can detect temperature values in the range of 0- 1000 °C are used in the system.
  • Thermocouples (101 ) are used so as to measure Tinlet and Tf values.
  • a thermocouple sensor (102) is used between the thermocouple (101 ) and the microprocessor (110).
  • the thermocouple sensor (102) transmits the values measured by the thermocouples (101 ) to the microprocessor (110) by converting the voltage values to degrees Celsius.
  • the temperature values can be measured with an accuracy of ⁇ 0.25 C with this thermocouple sensor (102), which is a bridge between the microprocessor (110) and the thermocouple (101 ).
  • the coolant is circulated by means of the pump (107) in the cooling system, which is in the form of a closed cycle.
  • the coolant is received from the fluid tank (108) and sent into the cutter base (122) by means of the pump (107) at the desired flow rates.
  • the DC pump driver (105) is used so as to control the pump (107).
  • the pump driver (105) can control the operating speed of the pump (107) by PID (proportional- integral-derivative controller control cycle method) method with the microprocessor (110).
  • PID proportional- integral-derivative controller control cycle method
  • the fluid is sent to the cutter tool (120) which is designed to increase its velocity proportionally.
  • the flow rate of the coolant is measured by means of a sensitive flow meter (106).
  • pumps (107) in the system There are also two more pumps (107) in the system. 2 further pumps (107) are adapted to the cooler unit (109) with a radiator and pelletizer so as to cool the fluid in the fluid tank (108). Therefore, in case the critical temperatures are reached, the fluid in the fluid tank (108) begins to be cooled with the microprocessor (110).
  • the LCD screen (103) is adapted to the module and is in direct communication with the microprocessor (110). Therefore, measured temperatures and the speed of the coolant can be monitored and followed by the operator.
  • the cooler unit (109) provides cooling of the fluid and consists of aluminum heat sinks, radiators, fans, and Peltier modules.
  • the cooler unit (109) is fed by the 12 V power supply (104).
  • the power source (104) ensures that the cooler unit (109) is switched on and off according to the commands received from the microprocessor (110). It is observed that Peltier modules in the cooler unit (109) generate electromagnetic noise during operation; they have distortion effects on the operation of the thermocouples (101). For this reason, the Peltier module of the cooler unit (109) is taken to the Faraday cage with an Al box. Therefore, electromagnetic effects are eliminated.
  • the microprocessor (110) in the inventive module operates with a method so as to smartly cool the tool tip (121 ) of the cutter tool (120) and to make an estimation.
  • the workflow diagram of the estimation method of the microprocessor (110) is shown in Figure-3.
  • the microprocessor (110) receives (10) fluid velocity (Vf), fluid temperature (Tinlet), and tool tip (121) side surface temperature (Tf) values measured by means of the flow meter (106) and the thermocouple sensor (102).
  • the microprocessor (110) evaluates the tool tip (121 ) temperature (Ttip) for different situations according to the calibration approach based on CFD-statistics according to these parameters (11 ).
  • the microprocessor performs four different examinations.
  • the microprocessor (110) does not transfer coolant to the cutter tool tip (121) and estimates (12) that the module is operating normally, in case Ttip value is between the maximum dry machining temperature (Td) and the minimum temperature (Tmin).
  • the microprocessor (110) sends (13) coolant to the cutter tool (120) by means of the pumps (107) in case the Ttip value is equal to or greater than the Td value and less than the maximum critical temperature (Ter) value.
  • the microprocessor (110) controls the speed of the coolant and operates (14) the cooling unit (109) and cooling of the coolant begins in the fluid tank (108), in case the Ttip value is greater than or equal to the maximum critical temperature (Ter) value.
  • the microprocessor (110) switches off the pumps (107) and stops (15) the fluid pumping and cooler unit (109), in case the Ttip value is less than and equal to Tmin values. Also, the microprocessor (110) prints the measurement value of the Ttip taken from the thermocouple sensor (102) to the LCD screen (103).
  • the self-cooling condition provided better cooling by 107 °C compared to dry conditions under the same limit conditions.
  • Ttip values could be kept constant for the maximum temperature level of the air in the Td-Tcr range.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Auxiliary Devices For Machine Tools (AREA)
  • Turning (AREA)

Abstract

The present invention relates to an internal cooling smart cutter tool module for cooling the cutter tool tip during the turning process. The present invention particularly relates to a smart cutter tool module comprising a smart control-cooler unit that has the ability to control and decide the flow rate/speed and temperature of the coolant sent into the cutter tool according to the extreme temperature values that it estimates according to its own operating strategy.

Description

SMART CUTTER TOOL MODULE FOR CNC LATHES
Technical Field of the Invention
The present invention relates to an internal cooling smart cutter tool module for cooling the cutter tool tip during a turning process.
The present invention particularly relates to a smart cutter tool module comprising a smart control-cooler unit that is capable of controlling and determining the flow rate/speed and temperature of the coolant transferred to the cutter tool according to the extreme temperature values that it estimates based on the operating strategy thereof.
State of the Art
The turning method is one of the most commonly used methods of machining. The turning process is the process of chip removal and shaping with a cutter tool that can move in different directions over a circular moving workpiece. While the workpiece performs the main movement by rotation, providing cutting depth and further movement is performed with the cutter tool. Lathes that perform turning processes are also called turning lathes. Generally, cylindrical and conical surfaces are processed in the external inner sections with axial movement during turning.
Various lathes are used for the turning process. Some of these lathes are as follows; universal lathe, vertical lathe, revolver lathe, air-diameter lathe, copy lathe, bench type lathe, and CNC-mass production lathe.
CNC lathes, unlike conventional lathes, are the lathes that produce workpieces serially in a short time with the determined measurement, progress, and revolutions by means of the ball screw and servo motor that move the axes with NC programs sent to a computerized control unit.
Thermal changes that occur at the sides of the cutter tool tips during the turning process cause wear, thermal erosion, measurement errors, an increase in surface roughness, and a decrease in tool tip life. The heat generated in the cutting zone during chip removal causes negative effects on the workpiece surface. The heat released during turning is a much more critical parameter for machinability particularly in materials actively used in industry such as nickel-based superalloys, titanium, composites, and high chromium white cast iron, which are difficult to process. High temperatures are observed and thus damage to the cutter tool tip is seen since these materials are difficult to process. Therefore, many studies in the state of the art have mentioned the importance of lowering the temperature in the cutting zone and extension of tool life with the decrease in the temperature, decrease in wearing of the tool tip, and the increase in quality of the machined surface. Furthermore, damage to the cutter tool tip has not yet been eliminated, many studies aimed to control many parameters during machining, especially cutting forces and temperature so as to reduce damages. Therefore, the use of traditional cutting fluids for cooling the cutting zone, cryogenic cooling, minimum quantity lubrication, use of high-pressure coolers, solid lubricants, air/gas-based lubricants, vegetable-based cutting fluids, and recently, promising internal cooling systems have been preferred. Internal cooling systems have started to be preferred due to the advantages that eliminate the negative effects imposed on the environment and worker health by means of cutting fluids or lubricants, reducing costs, expandable compact designs, ease of use, and accurate temperature measurements.
The problem generally occurs in lathes is heating of cutter tips and thus relevant mechanical and productivity problems. Therefore, cooling of these tips is very important. In the state of the art, there are various developments and inventions for the solution of this problem. Especially, estimating the temperature in the cutting zone and the ability to control cooling in that zone are still required. There are some aspects and some problems brought with these where solutions are not sufficient.
As a result of the preliminary research made about the state of the art, patent file No TR2019/22059 with the title “Internal Cooling Channel P-System, S-System External Turning Tools and End Cooling Nozzle Used in CNC Machines” was examined. In the summary section of the invention subject to application, it is stated that “The invention relates to bearing on the catheter body of end cooling nozzle and mounting the same from the bodyside surface in a stable manner by positioning on the cutting tip and the end cooling nozzle in CNC machines, in p-system, s- system external lathe tools giving internal coolant with which connected to the machine.”
As a result of the preliminary search conducted in the state of the art, the patent document numbered “CN100460113” was examined. In the invention subject to application, a cutter tool is disclosed. In the invention, a pipeline was opened under the cutter tool and liquid nitrogen was sent to the cutter tool tip from the bottom. Therefore, they mentioned that cooling is provided.
As a result of the preliminary search conducted in the state of the art, the patent document numbered “CN106270585” was examined. In the invention subject to application, a cutter tool is disclosed. A base is designed so as to pass the liquid through it to the cutter tool used for turning. The base consists of a liquid inlet, outlet, and channels in which the liquid cycles. It is assembled in two parts. The liquid cyclotron is rotated in the channel within the base and the base is cooled. The base is cooled since it is in contact with the cutter tool tip.
As a result of the preliminary search conducted in the state of the art, the patent document numbered “CN106270585” was examined. In the invention subject to the application, a cutter tool used for threading the outer surface in the lathe is disclosed. The invention comprises of a cutter tool tip consisting of triangular grooves and a channel through which coolant is transferred to the tip to cool the tip.
As a result of the preliminary search conducted in the state of the art, the patent document numbered “CN208033687” was examined. In the invention subject to the application, a cutter tool design with internal cooling has been introduced. In the invention, it is seen that the coolant is passed through the base. In this way, it cools the cutter tool tip. It is seen that the base takes the coolant fluid through the channel opened into the tool holder from the inlet and discharges the same through the drain hole. The coolant performs cooling by direct contact with the cutting tool tip.
As a result of the preliminary search conducted in the state of the art, the patent document numbered “CN209157165” was examined. In the invention subject to the application, channels are opened until a cavity is opened from the back of the tool holder in the cutter tool until the exit. A design in which the coolant is sprayed to the cutter tool tip through these channels is provided.
As a result of the preliminary search conducted in the state of the art, the patent document numbered “US5799553A” was examined. In the invention subject to application, the cutter tool is divided into two parts and a channel is opened through which the coolant fluid will pass. The cutting tool tip is cooled with the circulating fluid.
It is seen that water cycle channels with different geometries are used so as to cool the cutter tool tip when the cooling systems in the state of the art are examined in general.
In the state of the art, it is seen that there is a focus on the cutter tool design and production in different geometries with internal cooling. It appears that the coolant provides heat transfer by direct contact with the cutter tool or with an intermediate plate. The coolant, circulating in a closed cycle flows in the tool in different geometries, it was stated in the studies that significant cooling is provided on the cutter tool tip during machining.
In the state of the art, an internal cooling cutting tool design is used in some publications, a reservoir is opened under the cutter tool tip above the cutter tool holder and R-123 (hydrochlorocarbon) liquid is cycled from this reservoir. It is stated that R-123 transforms into the gas phase during the rotation of the same in the tool in a closed cycle and provides cooling. There is a copper plate between the cutter tool tip and the coolant.
A self-cooling tool is designed and produced so as to be able to process with a diamond-coated tip in a study carried out in the state of the art. The tool tip is adapted to a block by opening a channel with micro-machining from a location close to the cutting zone. Cooling is ensured by passing coolant through this channel. In this study that aims to prevent the tool tip from reaching the critical temperature accelerating the wear mechanisms, the temperature at the tool tip is measured with a pyrometer. In another study in the state of the art, it is aimed to develop a self-cooling smart cutter tool for turning process in dry conditions. In this study, where optimization was made with CFD and Taguchi methods during the design and production phase, an adapter is formed with a part that can be mounted under the cutter tool tip so as to cycle coolant through the cutter tool. There is a triangular channel in this adapter and fluid circulation is provided in this channel. Distilled water is used as a coolant. It continuously measures the inlet and outlet temperatures of the coolant and the Ttip values were determined according to the correlation between the inlet and outlet temperatures. The optimum processing parameters are determined for the CNC machine according to this temperature.
In a study conducted in the state of the art, a micro-channel is opened under the cutting tool tip for adapting a base and the fluid is cycled through this channel. These channels are positioned as close as possible to the tool tip. The temperature at the cutting tip is measured by means of thermocouples. While this fluid temperature is measured by means of the thermocouples, the coolant is cycled at a constant flow and a constant temperature by means of the pump through the microchannels. It can measure the inlet and outlet temperatures of the coolant. The optimum values are determined for different inlet temperatures and speeds that are manually adjustable.
In a study conducted in the state of the art, a closed-cycle cooling system has been integrated into the cutter tool. The cutting tip is cooled by passing the fluid taken from the cooling system through the channel opened to the tool holder in a spiral manner.
In a study conducted in the state of the art, a V-shaped channel was opened in the tool catheter and ensured cooling by cycling the fluid through the same. Furthermore, the temperature change between the tip and the chips is also monitored with a thermal camera.
It is seen that publications and patents in the state of the art focus on the water cycle channel or reservoir with different geometries with internal cooling. It appears that the coolant provides heat transfer by direct contact with the cutter tool or with an intermediate plate. In the studies conducted in the state of the art, it is seen that the coolant fluid in different geometries is rotated in the cutter tool. These methods do not have the ability to make self-decisions, to instantly control the parameters that affect the temperature of the tool tip and the machinability. The consumption of the coolant is not in a closed cycle in some methods. Therefore, its consumption is not restricted and increases the production cost. There is no estimation method that measures the temperature at the cutter tool tip accurately in the methods. It is difficult to adapt the same to standard manufactured cutter tool tips. Specific tool tip production is required in some methods, this will increase the cost of the cutter tool production. It is not controlled whether sufficient cooling is provided in each design. They do not have the ability to estimate the cutting tool tip temperature, to control the cooling as part of the cooling strategy based on the estimated temperature.
In some studies used in the state of the art, Ttip temperature is determined according to the inlet and outlet temperatures of the coolant. There are still many parameters that affect Ttip values. These parameters are like the type and speed of the coolant, thermal properties of the cutter tool, and environmental conditions. Therefore, determining Ttip values only by correlation is not a sufficient approach.
Consequently, the aforementioned disadvantages and the insufficiency of the available solutions in this regard necessitated making an improvement in the relevant technical field.
Objects of the Invention
The most important object of the present invention is to ensure that the invention comprises an internal cooling smart cutter tool module aimed at cooling the cutter tool tip during the turning process.
Another important object of the present invention is to estimate the temperature formed at the cutter tool tip by measuring the side surface temperature of the cutter tool tip, the inlet temperature, and the inlet flow rate of the coolant circulating in the closed cycle system. The smart control-cooling unit has the ability to control and decide the flow rate/speed and temperature of the coolant sent into the cutter tool according to the extreme temperature values that it estimates according to its own operating strategy.
Yet another object of the present invention is to ensure that it has no negative effects on the health of the operator and to be environmentally friendly.
Another object of the present invention is to ensure that it has a modular structure that can either be used on traditional lathes or mounted as a further module on CNC lathes.
Another object of the present invention is to ensure that the system has its own working and calibration strategy and allows the operator to determine the operating temperatures. Therefore, it ensures that the cutter tool tip is kept within the specified temperature range during machining.
Another object of the present invention is to provide a base with specific geometry for the cutter tool tip. Therefore, the base directly contacts the fluid with the cutter tool tip, thus makes the cooling more efficient.
Another object of the present invention is to enable the use of any type of coolant.
Another object of the present invention is to ensure that it has its own calibration method based on CFD statistics. Thus, tool tip temperature estimations can be customized according to coolant and cutter tool types and the accuracy of the estimation can be increased.
Another object of the present invention is to ensure that it has a microprocessor that runs software that can enter commands. Thus, it can keep the cutter tool tip temperature constant in the temperature range determined by the operator under certain cutting conditions.
Another object of the present invention is to ensure that it can be adapted to any type of standard cutter tool tip with its base design located on the cutter tool tip.
Structural and characteristic features of the present invention will be understood clearly by the following figures and the detailed description written with reference to these drawings. Therefore the evaluation should be conducted by taking these figures and the detailed description into consideration.
Description of the Figures
FIGURE-1 ; illustrates the general view of the inventive system. FIGURE-2; illustrates the view of the inventive cutter tip of the smart cutter tool module.
FIGURE-3; illustrates the workflow view of the estimation method of the inventive module.
Reference Numbers 101. Thermocouple
102. Thermocouple Sensor
103. LCD Screen
104. Power Source
105. Pump driver 106. Flowmeter
107. Pump
108. Fluid Tank
109. Cooler Unit
110. Microprocessor 120. Cutter tool
121. Tool Tip 122. Tool Base
123. Fluid Inlet
124. Fluid Outlet
10. Obtaining the measured fluid velocity, fluid temperature, and tool tip side surface temperature values by the microprocessor.
11. Evaluating the tool tip temperature by the microprocessor.
12. Not sending coolant to the cutter tool tip and estimating that the module is operating normally by the microprocessor.
13. Sending coolant to the cutter set with pumps by the microprocessor.
14. Controlling the speed of the coolant and operating the cooling unit by the microprocessor.
15. Stopping pumping and cooling the fluid by turning off the pumps by the microprocessor.
Description of the Invention
The present invention relates to an internal cooling smart cutter tool module for cooling the cutter tool tip (121) during the turning process. The module can either be used on traditional lathes or mounted as a further module on CNC lathes. This module can estimate the temperature (Ttip) formed at the cutter tool tip (121) by measuring the side surface temperature (Tf) of the cutter tool tip (121), the inlet temperature (Tinlet), and the inlet flow rate (Vf) of the coolant circulating in the closed cycle system.
Parameters that affect the basic heat transfer such as the thermal properties of the cutter tool (120) and the coolant, ambient temperature, the inlet temperature of the coolant, flow rate are considered. Furthermore, these parameters can be changed according to the coolant and cutter tool (120) types. For this reason, the inventive module comprises a microprocessor (110) having a calibration approach based on CFD-statistics (Computational Fluid Dynamics, Calculated fluid dynamics) and its own operating strategy by cooling the cutting tool (120) cutting edges.
The coolant directly contacts the cutter tool (120) so as to effectively cool the cutter tool tip (121 ). For this reason, there is a fluid inlet (123) with an inclined surface for spraying coolant towards the chip contact area of the cutter tool tip (121) and the fluid outlet (124) that discharges the coolant on the cutting tool base (122). The coolant cycled in the system is required to contact the cutter tool tip (121 ) as much as possible. Therefore the volume of the fluid tank (108) where the fluid cooling the system is stored is designed as large as possible.
The tool base (122) of the cutter tool (120) shown in Figure-2 is manufactured from stainless steel in dimensions suitable for the tool tip (121 ). Sealing between the tool tip (121) and the tool base (122) is provided by a gasket in the form of a thin film.
The inventive tool module with internal cooling cooling-control system mainly consists of the following; thermocouple (101 ), thermocouple sensor (102), LCD Screen (103), power source (104), pump driver (105), flow meter (106), pump (107), fluid tank (108), cooler unit (109), microprocessor (110) and cutter tool (120).
First of all, the cooling-control system of the inventive module switches on and off the module at the critical temperature values determined by the operator and transmitted to the microprocessor (110). The microprocessor (110) of the module is capable of controlling the speed of the coolant sent into the tool base (122). In other words, when the temperature of the tool tip (121) increases, the coolant must be cycled faster in the module. Thus, there will be more efficient heat transfer. In this sense, the system has been designed and produced in two parts. Firstly, it receives feedback from the speed (Vf) of the coolant, its temperature (Tinlet), and the tool tip (121 ) side surface temperature (Tf) values and determines the cooling strategy. The other part of the module is responsible for cooling the coolant. The operating scheme of the entire system is shown in figure-1 .
The cooling-control system has three main services. These services are controlled by the microprocessor (110). Vf, Tinlet, and Tf values received by the flow meter (106) and thermocouple sensor (102) are transmitted to the microprocessor (110) and the microprocessor (110) is enabled to estimate the tool tip (121) temperature (Ttip). Furthermore, the microprocessor (110) enables the cooling system to operate when critically extreme temperatures are observed. The microprocessor (110) operates the pumps (107) with the PID control and ensures that fluid is sent to the cutter tool base (122) at different speeds in accordance with the increase in the Ttip value. The entire system is fed with a 12 V power supply (104) and all electronic parts are in contact with the microprocessor (110). The microprocessor (110) directly interacts with K- type thermocouples (101 ), thermocouple sensors (102), LCD screen (103), DC pump drivers (105), flow meter (106), and cooler unit (109) and receives feedback from each of them.
K-type thermocouples (101 ) that can detect temperature values in the range of 0- 1000 °C are used in the system. Thermocouples (101 ) are used so as to measure Tinlet and Tf values. A thermocouple sensor (102) is used between the thermocouple (101 ) and the microprocessor (110). The thermocouple sensor (102) transmits the values measured by the thermocouples (101 ) to the microprocessor (110) by converting the voltage values to degrees Celsius. The temperature values can be measured with an accuracy of ± 0.25 C with this thermocouple sensor (102), which is a bridge between the microprocessor (110) and the thermocouple (101 ).
The coolant is circulated by means of the pump (107) in the cooling system, which is in the form of a closed cycle. The coolant is received from the fluid tank (108) and sent into the cutter base (122) by means of the pump (107) at the desired flow rates. The DC pump driver (105) is used so as to control the pump (107). The pump driver (105) can control the operating speed of the pump (107) by PID (proportional- integral-derivative controller control cycle method) method with the microprocessor (110). In other words, as the Ttip values estimated by the microprocessor (110) increase, the fluid is sent to the cutter tool (120) which is designed to increase its velocity proportionally. The flow rate of the coolant, thus the flow rate, is measured by means of a sensitive flow meter (106). There are also two more pumps (107) in the system. 2 further pumps (107) are adapted to the cooler unit (109) with a radiator and pelletizer so as to cool the fluid in the fluid tank (108). Therefore, in case the critical temperatures are reached, the fluid in the fluid tank (108) begins to be cooled with the microprocessor (110). The LCD screen (103) is adapted to the module and is in direct communication with the microprocessor (110). Therefore, measured temperatures and the speed of the coolant can be monitored and followed by the operator.
The cooler unit (109) provides cooling of the fluid and consists of aluminum heat sinks, radiators, fans, and Peltier modules. The cooler unit (109) is fed by the 12 V power supply (104). The power source (104) ensures that the cooler unit (109) is switched on and off according to the commands received from the microprocessor (110). It is observed that Peltier modules in the cooler unit (109) generate electromagnetic noise during operation; they have distortion effects on the operation of the thermocouples (101). For this reason, the Peltier module of the cooler unit (109) is taken to the Faraday cage with an Al box. Therefore, electromagnetic effects are eliminated.
The microprocessor (110) in the inventive module operates with a method so as to smartly cool the tool tip (121 ) of the cutter tool (120) and to make an estimation. The workflow diagram of the estimation method of the microprocessor (110) is shown in Figure-3. In the estimation method of the microprocessor (110), firstly the microprocessor (110) receives (10) fluid velocity (Vf), fluid temperature (Tinlet), and tool tip (121) side surface temperature (Tf) values measured by means of the flow meter (106) and the thermocouple sensor (102). The microprocessor (110) evaluates the tool tip (121 ) temperature (Ttip) for different situations according to the calibration approach based on CFD-statistics according to these parameters (11 ). The microprocessor performs four different examinations.
The microprocessor (110) does not transfer coolant to the cutter tool tip (121) and estimates (12) that the module is operating normally, in case Ttip value is between the maximum dry machining temperature (Td) and the minimum temperature (Tmin).
The microprocessor (110) sends (13) coolant to the cutter tool (120) by means of the pumps (107) in case the Ttip value is equal to or greater than the Td value and less than the maximum critical temperature (Ter) value. The microprocessor (110) controls the speed of the coolant and operates (14) the cooling unit (109) and cooling of the coolant begins in the fluid tank (108), in case the Ttip value is greater than or equal to the maximum critical temperature (Ter) value. The microprocessor (110) switches off the pumps (107) and stops (15) the fluid pumping and cooler unit (109), in case the Ttip value is less than and equal to Tmin values. Also, the microprocessor (110) prints the measurement value of the Ttip taken from the thermocouple sensor (102) to the LCD screen (103).
In chip removing processes using self-cooling cutter tools (120), although the main factor of temperature rise at the tool tip (121 ) is heat, other parameters such as the material of the cutter tool (120), the properties of the cutting fluid, and flow rate and environmental conditions, etc. affect the Ttip value. For this reason, in an embodiment of the inventive module, Different experimental conditions are simulated by constructing the behavior of the cutter tool (120) by a CFD model. CFD simulation after experimental verification, calibration curves were obtained by obtaining Tf values for dry and internal cooling conditions solved for different Ttip values. The cutter tool tip (121) was heated with the soldering iron, the produced prototype was observed and the following results were obtained during the experiments. CFD-statistics-based calibration strategy for the designed cutter tool (120) is provided by taking into account the parameters that affect the Ttip values. This strategy can be used for different tip types. Furthermore, the operator can determine the Td, Ter and Tmin values himself/herself.
The self-cooling condition provided better cooling by 107 °C compared to dry conditions under the same limit conditions. Also, Ttip values could be kept constant for the maximum temperature level of the air in the Td-Tcr range.

Claims

1. An internal cooling smart cutter tool module for cooling the cutter tool tip (121) during the turning process, characterized in that, it comprises;
• Thermocouple (101) that ensures the fluid temperature and tool tip (121) side surface temperature to be measured,
• Thermocouple sensor (101) that is located between the thermocouple (101 ) and a microprocessor (110) and transmits the values measured by the thermocouples (110) to the microprocessor (102) by converting the voltage values to degrees Celsius,
• LCD screen (103) that is in direct connection with the microprocessor (110) and ensures the temperatures and the speed of the coolant to be displayed,
• Power source (104) that provides the required energy to the module and ensures the cooler unit (109) to be switched on and off according to the commands it receives from the microprocessor (110),
• Pump driver (105) that is used to control the pump (107) and enables the microprocessor (110) to control and adjust the operating speed of the pump (107),
• Flowmeter (106) that measures the flow rate of the coolant, thus the flow rate,
• Pump (107) that provides circulation of the cooling fluid in the cooling system in the form of a closed cycle, ensures that the cooling fluid is taken from the fluid tank (108) and sent into the cutter base (122) at desired flow rates, is controlled by pump driver (105),
• Fluid tank (108) that stores the fluid cooling the system,
• Cooler unit (109) that provides cooling the fluid, is fed by a power supply (104) consisting of aluminum heat sinks, radiator, fans, and Peltier module,
• Microprocessor (110) that enables the inventive module to be switched on and off at critical temperature values determined by the operator, is able to control the speed of the coolant sent into the tool base (122), estimates the tool tip (121) temperature (Ttip) according to the velocity (Vf) of the fluid, the fluid temperature (Tinlet) and the side surface temperature (Tf) of the tool tip (121 ) received by the flow meter (106) and the thermocouple sensor (102), drives the pumps (107) with the pump driver (105) and allows the fluid to be sent to the cutter tool base (122) at different speeds according to the increase in the tool tip (121) temperature (Tty), interacts with thermocouples (101), thermocouple sensors (102), LCD display (103), pump drivers (105), flow meter (106) and cooling unit (109) and receives feedback from each of them,
• Cutter tool (120) that comprises cutter tool base (122) which has a fluid inlet (123) with curved surface to spray coolant towards the chip contact area of the cutter tool tip (121) and the fluid outlet (124) that drains the coolant on it and tool tip (121) and directly contacts with the coolant.
2. Smart cutter tool module according to claim 1 , characterized in that; method for estimating the tool tip (121) temperature (Ttip) of the microprocessor (110) comprises process steps of;
- Obtaining (10) the measured fluid velocity (Vf), fluid temperature (Tinlet), and tool tip (121) side surface temperature (Tf) values by the microprocessor (110),
- Evaluating (11) the temperature (Ttip) of the tool tp (121) by the microprocessor (110),
- Not sending coolant to the cutter tool tip (121) and estimating (12) that the module is operating normally by the microprocessor (110), in case the tool tip (121) temperature (Ttip) value is between the maximum dry machining temperature (Td) and the minimum temperature (Tmin),
- Sending (13) coolant to the cutter tool (120) by means of the pumps (107) by the microprocessor (110) in case the tool tip (121 ) temperature (Ttip) value is equal to or greater than the Td value and less than the maximum critical temperature (Ter) value,
- Controlling (14) the speed of the coolant and operating the cooling unit (109) by the microprocessor (110), in case the tool tip (121 ) temperature (Ttip) value is greater than or equal to the maximum critical temperature (Ter) value, - Starting to cool the coolant in the fluid tank (108),
- Shutting off the pumps (107) and stopping (15) the fluid pumping and cooling by the microprocessor (110), in case the tool tip (121) temperature (Ttip) value is less than and equal to Tmin values; - Printing the measurement value of the tool tip (121) temperature (Ttip) received from the thermocouple sensor (102) to the LCD screen (103) by the microprocessor (110).
3. Smart cutter tool module according to claim 1, characterized in that; it comprises a microprocessor (110) having CFD-statistics-based calibration approach and its own operating strategy.
4. Smart cutter tool module according to claim 1 , characterized in that; it comprises a thermocouple sensor (102) that serves as a bridge between the microprocessor (110) and the thermocouple (101) and can measure the temperature values with a sensitivity of ±0.25 °C.
5. Smart cutter tool module according to claim 1, characterized in that; it comprises K-type thermocouples (101) that can detect temperature values in the range of 0-1000 °C.
6. Smart cutter tool module according to claim 1, characterized in that; it comprises a microprocessor (110) that enables the cooling unit (109) to be switched on and off by sending a command to the power source (104).
7. Smart cutter tool module according to claim 1 , characterized in that; it comprises an aluminum box housing the Peltier module, which prevents the electromagnetic noise created by the Peltier modules during operation and the disruptive effect of the operation of the thermocouples (101) connected to it.
8. Smart cutter tool module according to claim 1, characterized in that; it comprises a tool base (122) made of stainless steel and produced in suitable dimensions for the tool tip (121 ).
9. Smart cutter tool module according to claim 1, characterized in that; it comprises a gasket in the form of a thin film that provides sealing between the tool tip (121 ) and the tool base (122).
PCT/TR2021/050387 2020-04-27 2021-04-26 Smart cutter tool module for cnc lathes WO2021221586A1 (en)

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CN116604396A (en) * 2023-06-25 2023-08-18 中国地质大学(北京) Device for prolonging service life of high-speed dry cutting tool and use method
CN117583946A (en) * 2023-12-01 2024-02-23 浙江晨业金属科技有限公司 Intelligent cutting device and cutting method for stainless steel flange

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CN114669770A (en) * 2022-04-20 2022-06-28 浙江浪潮精密机械有限公司 Intelligent cutting tool structure and using method
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CN117583946A (en) * 2023-12-01 2024-02-23 浙江晨业金属科技有限公司 Intelligent cutting device and cutting method for stainless steel flange

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