Mathematical Modeling of Coolant Flow in Discontinuous Drilling Processes with Temperature Coupling

Nickel-based alloys, like Inconel 718, are widely used in industrial applications due to their high-temperature strength and high toughness. However, machining such alloys is a challenging task because of thermal loads at the cutting edge thus extensive tool wear expected. Consequently, development new process strategies needed. We will consider discontinuous drilling with coolant. The main idea interrupt order let coolant flow around reduce loads. Since measurements inside borehole (nearly) impossible, simulations key analyze understand proposed process. In this paper, 3D fluid simulation model Q2P1 Finite Elements combination Fictitious Boundary Method presented simulate drill borehole. underlying equations transformed into rotational frame reference overcoming challenges mesh design for domains domain. Special treatment Coriolis forces developed, that modifies ‘Pressure Poisson’ Problem projection step improving solver angular velocities. To further take velocities account, two-scale artificial diffusion technique introduced stabilize simulation. Finally, Q1 heating cooling processes both during complete split ‘contact’ ‘no contact’ phase coupling strategy between these phases developed. FBM utilized switch two configurations, only one unified grid configurations results gain insight optimize design.