Numerical investigation for improving inflow conditions of the internal coolant supply (ICS) for circular saws

Abstract The increasing demands in manufacturing technology require continuous improvement of machining processes. The use of internal coolant supply (ICS) has led to enhanced efficiency in circular sawing by enabling more uniform chip cooling, particularly when machining difficult-to-cut materials. However, integrating coolant channels into the thin-walled core bodies of the circular saw blade poses significant manufacturing challenges and introduces additional risks in circular saw blade production. To reduce manufacturing effort, this study aims to improve the geometry of circular saw blades for ICS-based machining using numerical flow simulation. In particular, the investigation focuses on modifying the inflow geometry to reduce the number of coolant channels required to improve the process and establish an enhanced fluid flow between the chip spaces of the saw blade. Various inlet conditions and geometric configurations are analyzed and evaluated regarding the ability to supply chip spaces with no direct cooling channel with respect to their manufacturing complexity.