Optimized Thermal Dissipation of ISO SNGA 120408 Carbide Tool by Tuning Parameters: A Numerical Study

ABSTRACT

In metal cutting, excessive heat generation adversely impacts tool life, dimensional accuracy, and the metallurgical properties of the workpiece, highlighting the necessity for thermal management of the cutting insert. This study numerically investigates key thermal management parameters, including air velocity, insert hole size, and the impact angle of the cooling air, with the objective of minimizing tool tip temperature during turning operations, using a Conjugate Heat Transfer (CHT) model in COMSOL Multiphysics. The study introduced and analyzed two previously unexplored parameters, insert hole size and impact angle, both individually and in combination with air velocity to evaluate their combined effects on thermal dissipation. The individual effects of air velocity (0.2–10 m/s), insert hole size (0.103–0.303 inch), coolant impact angle (0°–90°), and four cooling media (air, water, alumina mist, and Al‐MWCNT mist) on tool tip temperature are evaluated for the ISO SNGA120408 (ANSI SNGA 432) uncoated carbide turning insert using the shear stress transport (SST) turbulence model. A boundary heat source of 7.03 W is applied at the tool‐chip contact zone, based on a cutting speed of 100 m/min, feed rate of 0.3 mm/rev, and depth of cut of 1 mm, with heat partitioned in a 10:10:80 ratio among the tool, workpiece, and chip. Results indicate that increased air velocity substantially enhances convective heat transfer, while larger hole sizes and optimal impact angles are most effective at lower velocities. For instance, increasing the insert hole size reduces the tool tip temperature from 792.76 to 746.02 K, and favorable temperatures are achieved at a 45° impact angle. At air velocities above 5 m/s, the influence of hole size and angle becomes negligible. The optimal cooling configuration—5 m/s air velocity, 45° impact angle, 0.303 inch insert hole, and water as the coolant—reduces the tool tip temperature to 470.86 K. This study establishes a comprehensive framework for improved thermal control in machining processes.