Influence of Micro-Textures on Cutting Insert Heat Dissipation

Round 1

Reviewer 1 Report

  The influence of micro-textures on cutting insert heat dissipation is an intriguing topic for a research paper. As far as I am aware, this method can reduce thermal stress during manufacturing. Although this paper has an acceptable structure, it is severely lacking in method and mathematical background information.

1-       The abstract requires more qualitative value. Please describe more details. The majority of abstract text is appropriate for introductions.

 

2-       The numerical specifics in the present manuscript are abysmal. The authors should provide details regarding grid study, validation, and calculation, including mass flow rate and boundary condition. Ansys fluent is a commercial software (NOT a code), so the author of this method must provide specifics.

Author Response

The authors appreciate the feedback provided by reviewer. It has proved valuable to increase the clarity of the manuscript.

General Comments- " The influence of micro-textures on cutting insert heat dissipation is an intriguing topic for a research paper. As far as I am aware, this method can reduce thermal stress during manufacturing. Although this paper has an acceptable structure, it is severely lacking in method and mathematical background information.”

 

Response: We appreciate the comment, and we tried to do our best to improve the clarity and conciseness of the paper. To justify the line of the research proposed in this work and introduce more background information, we now include an extensive revision about the increase in tools performance produced by the surface nano- and micro-textures.

Comment 1:“ The abstract requires more qualitative value. Please describe more details. The majority of the abstract text is appropriate for introductions.”

Response: Thank you for your suggestions. We revised the abstract according to the reviewer's comments by removing the following two sentences: “The competitive market has motivated the constant search for new ways to improve the cutting process efficiency, mainly for high-performance materials. These are often associated with extreme cutting temperatures, resulting in lower manufacturing productivity and the reduced lifespan of tools.”

and by adding more details about the experimental tests and quantitative results, being two more sentences were added: “The square grid pattern of 100 μm×100 μm with grooves depths of 50, 100 and 150 μm was introduced on cutting insert surfaces by laser ablation. The experimental results show that there is a linear increase in the heat transfer rate with the depth of the grooves, which is justified by the improvement in surface wettability. “

Comment 2:“  The numerical specifics in the present manuscript are abysmal. The authors should provide details regarding grid study, validation, and calculation, including mass flow rate and boundary condition. Ansys fluent is a commercial software (NOT a code), so the author of this method must provide specifics.”

Response: The reviewer is right. We replace the text “finite volume method (FVM) code” with “ commercial software Ansys Fluent ® “

Regarding the numerical simulation, the number of polyhedral mesh elements, the mass flow rate, the convection coefficients, the thermal conductance, the mass density and the thermal properties are already given in the text and Table 1. To make it even clearer, the following text was added before Figure 2.

“The final values were obtained by applying the heuristic method. After a few iterations, a new convection coefficient of 10 W/m2.K was considered for the main body (1) and 25 W/m2.K for the heat sources (6). The thermal conductance final values between the heat sources (7) and the resistive elements (7) of 67467 W/m2.K and between the support seat (2) and the cutting insert (3) of 6325 W/m2.K. The remaining values were kept unchanged.”

“Numerical simulations were conducted for a steady regime by considering the previously described mesh and values of convection coefficients and thermal conductance, and the mass density and thermal properties of the materials presented in table 1. A constant mass flow rate of 15.6 g/s of water was considered for all the simulations. “

Reviewer 2 Report

The topic of the research work and manuscript is really interesting and provides new information. the text is well-written. However there are several issues to be addressed towards its quality improvement. In the introduction, as well as in the whole text, you should provide more details on the word "chip" that you use (for example, do you mean residual wood chip/metal chip or another material?). The state-of-the-art description could be improved incorporating significant findings of relevant studies in literature. I would propose to the authors to incorporate relevant information also from a study entitled "Lathe tool - It's development from the ancient times to nowadays". What kind of fluids could be used in the monitoring of temperature during cutting process or which could be used as coolant ones? Please provide also the potential applications on specific cutting tools (for example, lathe, jigsaw, milling cutter, band saw, circular saw, drill, cad etc.). In figure 1, refer also to applications of this CAD model presented. In table 1 you could present only 2 decimals in the values and provide as well the standard deviation values of these properties. The results and conclusions are generally well-presented and the graph provided very useful to the reader. I would propose to add a brief comment in conclusions highlighting the significance of the findings of the current work, future applications etc. The reference list should be changed following the format of the journal.

Author Response

We appreciate the comment, and we tried to do our best to improve the clarity and conciseness of the paper.

Comment 1: “In the introduction, as well as in the whole text, you should provide more details on the word "chip" that you use (for example, do you mean residual wood chip/metal chip or another material?)”

Response: The word “chip” is a word normally associated to metal. We don’t feel the need to associated to metal since we only describe the machining of metal 

Comment 2: “The state-of-the-art description could be improved incorporating significant findings of relevant studies in literature. I would propose to the authors to incorporate relevant information also from a study entitled "Lathe tool - It's development from the ancient times to nowadays".”

Response: The introduction was fully revised to incorporate the state-of-the-art research work. 

Comment 3: “What kind of fluids could be used in the monitoring of temperature during cutting process or which could be used as coolant ones?”

Response: Any fluid can be used to monitor temperature as long as its thermal properties are known.

Comment 4: “Please provide also the potential applications on specific cutting tools (for example, lathe, jigsaw, milling cutter, band saw, circular saw, drill, cad etc.).”

Response: The study is independent of the application of the cutting tool since the micro-textures are used in tools for turning and milling.

 

Comment 5: “In figure 1, refer also to applications of this CAD model presented. In table 1 you could present only 2 decimals in the values and provide as well the standard deviation values of these properties.”

 

Response: The values in table 1 are now presented in two decimals, as requested by the reviewer. The values shown are average values. Regarding the standard deviation, it is not usual to present, as these values are not known.

Comment 6: “I would propose to add a brief comment in conclusions highlighting the significance of the findings of the current work, future applications etc. The reference list should be changed following the format of the journal.”

Response: Thank you for the comment. The abstract and the conclusion have been revised to highlight the findings. 

Reviewer 3 Report

 

The work presents an experimental setup to study the impact of the tool surface characteristics on heat transfer rate. The paper is well written and has the correct structure. Its scope is suitable for Applied Sciences. However, the following comments should be addressed before publication:

-        - The introduction with state-of-the-art is appropriate. However, the paper is missing a clear statement on the research's novelty. The new knowledge that is presented in this research should be discussed concerning state-of-the-art.

-        - Main dimensions of the proposed stand should be presented.

-        - Heat transfer enhancement mechanisms for tools with surface micro-textures should be explained and discussed.

 

Author Response

The authors appreciate the feedback provided by the reviewer. It has proved valuable to increase the clarity of the manuscript.

The work presents an experimental setup to study the impact of the tool surface characteristics on heat transfer rate. The paper is well written and has the correct structure. Its scope is suitable for Applied Sciences. However, the following comments should be addressed before publication:

 

- The introduction with state-of-the-art is appropriate. However, the paper is missing a clear statement on the research's novelty. The new knowledge that is presented in this research should be discussed concerning state-of-the-art.

 

Response: We follow the reviewer’s suggestion and include more information on the latest research work about the effect on tool performance produced by the surface nano- and micro-textures.

 

- Main dimensions of the proposed stand should be presented.

 

Response: We have already included a scale or ruler in all images and photos for the reader to perceive the main dimensions of the system. However, if the reviewer feels it is critical, we can include a new figure of the 3D CAD model with its main dimensions.

 

- Heat transfer enhancement mechanisms for tools with surface micro-textures should be explained and discussed.

Response: The introduction section has been completely revised to include a more detailed review of the state-of-the-art and to explain the heat transfer improvement mechanism.

Reviewer 4 Report

Authors are recommended to include following points.

- The abstract lack quantitative highlights of the study.

- The title needs more description about problem, now it looks quite general. 

-Introduction is based on general understandings, similar studies should be introduced and compared to drive towards current problem statement. 

In following study, authors machined a hard to cut material and discussed surface evolution, doi.org/10.3390/met11111751 Please include discussion on experimental results with respect to surface integrity by doing any experimental test.

-How authors evaluated statistical significance?

-How did authors optimize the design of pattern? 

 

Good luck

Author Response

The authors appreciate the feedback provided by the reviewer. It has proved valuable to increase the clarity of the manuscript.

 

Comment 1: “ The abstract lack quantitative highlights of the study.”

Response: The abstract and the conclusion have been revised to highlight the findings.

Comment 2: “  The title needs more description about problem, now it looks quite general.”

Response: We understand the reviewer's point of view. However, we believe that the title should be concise. Furthermore, the study carried out on heat transfer is generic and can be applied to any type of cutting insert.

Comment 3 “Introduction is based on general understandings, similar studies should be introduced and compared to drive towards current problem statement.”

Response: The introduction was fully revised to incorporate the state-of-the-art research work.

Comment 4: “In following study, authors machined a hard to cut material and discussed surface evolution, doi.org/10.3390/met11111751 Please include discussion on experimental results with respect to surface integrity by doing any experimental test.”

Response: The objective of this work is to develop a device capable of evaluating the increase in the heat transfer rate from the surface of the cutting insert to the coolant. The texture geometry affects the surface wettability and, through this, a greater efficiency in its cooling is obtained. Future works will be devoted to geometry optimization. After these, wear tests of the cutting insert will be carried out.

Comment 5: “-How authors evaluated statistical significance?”

Response: The statistical significance wasn’t evaluated, since we have a low number of experimental measurements. This will be addressed in the future by using more samples.

Comment 6 “How did authors optimize the design of pattern?”

Response: This is outside the scope of this work. The present work is part of broader research that seeks to increase the heat transfer rate by improving the surface wettability of cutting inserts, through the introduction of micro-textures. This topic will be addressed in the future.

Round 2

Reviewer 1 Report

I can advise this paper for publication based on the revised version.

Author Response

The authors are grateful for the feedback provided by the reviewer, it was important to improve the quality manuscript.

The text was fully revised to improve the clarity of the manuscript and correct the grammatical errors.

Reviewer 2 Report

As I have checked the revised version o f the manuscript, several changes have been implmeneted, though there are several issues to be addressed (even though the authors in their responses to the comments file say that they have addressed them). In table 1 you should present the standard deviation values of these properties. The proposed relevant study "Lathe tool - It's development from the ancient times to nowadays" has not been incorporated in the text. Please, check again all the comments one by one to address these issues and make a general check for grammatical and type errors in the whole text towards the improvement of the manuscript.  

Author Response

We appreciate the comments and we tried to do our best to improve the manuscript. 

Comment 1: “In table 1 you should present the standard deviation values of these properties.”
Response: As requested by the reviewer, the standard deviation values of the properties were added to table 1. 

Comment 2: “The proposed relevant study "Lathe tool - It's development from the ancient times to nowadays" has not been incorporated in the text”
Response: This reference was incorporated in the text. 

Comment 3: “Please, check again all the comments one by one to address these issues and make a general check for grammatical and type errors in the whole text towards the improvement of the manuscript.”
Response: The text was fully revised to improve the clarity of the manuscript and correct the grammatical errors

Reviewer 3 Report

 

The Authors corrected the paper. Now it may be accepted in its current form.

Author Response

The authors are grateful for the feedback provided by the reviewer, it was important to improve the quality manuscript.

 

Reviewer 4 Report

Thanks for revisions. 

Author Response

The authors are grateful for the feedback provided by the reviewer, it was important to improve the quality manuscript.

The text was fully revised to improve the clarity of the manuscript and correct the grammatical errors.