Enhancement of Groove Turning Performance by Additively Manufactured Tool Holders with Internal Cooling Channels and Combined Cooling Strategies

6 Pages Posted: 11 Nov 2021 Last revised: 29 Nov 2021

See all articles by Victor Lubkowitz

Victor Lubkowitz

Karlsruhe Institute of Technology

Nitin Reothia

Karlsruhe Institute of Technology

Frederik Zanger

Karlsruhe Institute of Technology (KIT) - Institute of Production Science; Karlsruhe Institute of Technology

Date Written: December 1, 2021

Abstract

Additively manufactured machining tools allow new concepts for internal cooling channels. Commercially available grooving tool holders with two connected channels carry fluids to the cutting zone and tool flank. This study compares commercial and newly designed tool holders. The new design provides two separate channels with the option to carry different media to the primary and secondary cutting edge. Different cooling strategies (flood cooling (FC), cryogenic cooling (LN2), minimum quantity lubrication (MQL), and combinations of them) were performed on the material Ti-6Al-4V (3.7165) to validate the performance and lifetime increase of the tool inserts. The test results show that the secondary edge cooling as well as combined cooling strategies reduce wear by up to 12 %. Neither LN2 nor LN2 combined with MQL are suitable for this process and tool design, but the combination of FC and MQL leads to a cutting length greater than 10000 m at 20 % higher productivity and the same reproducible surface roughness Rz of approx. 1 μm compared to commercially available grooving tool.

Keywords: Grooving, Cooling Lubrication Strategies, Laser Powder Bed Fusion (LPBF)

Suggested Citation

Lubkowitz, Victor and Reothia, Nitin and Zanger, Frederik, Enhancement of Groove Turning Performance by Additively Manufactured Tool Holders with Internal Cooling Channels and Combined Cooling Strategies (December 1, 2021). Proceedings of the Machining Innovations Conference for Aerospace Industry (MIC) 2021, Available at SSRN: https://ssrn.com/abstract=3922719 or http://dx.doi.org/10.2139/ssrn.3922719

Victor Lubkowitz (Contact Author)

Karlsruhe Institute of Technology ( email )

Kaiserstraße 12
Karlsruhe, Baden Württemberg 76131
Germany

Nitin Reothia

Karlsruhe Institute of Technology ( email )

Kaiserstraße 12
Karlsruhe, Baden Württemberg 76131
Germany

Frederik Zanger

Karlsruhe Institute of Technology (KIT) - Institute of Production Science ( email )

Germany

Karlsruhe Institute of Technology ( email )

Kaiserstraße 12
Karlsruhe, Baden Württemberg 76131
Germany

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