Design and Experiment of an Internally Cooled Turning Tool

Environmentally conscious machining is a current trend in the world. In order to minimize the impact of the cooling fluid in the machining process on the environment, the operator’s health as well as reduce the machining cost, many solutions have been proposed. One of the promising solutions is the application of cutting tools with internal coolant lines. This paper introduces a design of a turning tool with an internal coolant line. A K- type thermocouple sensor is installed in the tool insert to measure its internal temperature during turning. The relationship between the cutting temperature at the insert tip and the temperature inside the insert has been established experimentally. This study also evaluated the influence of the cutting regime parameters (cutting speed, feed rate, depth of cut) on the cutting temperature in the insert and the machined surface roughness when turning A6061 aluminum in two cases of dry turning and turning by internally cooled turning tool (ICTT). Experimental results show that there is a significant difference between the cutting temperature at the tip and the temperature inside the insert. The temperature in the insert and the machined surface roughness when turning by the ICTT are both reduced compared to that of dry turning. In both dry turning and turning by ICTT, feed rate is the main factor affecting surface roughness. In dry turning, the effect of depth of cut on the cutting temperature in the tool is greatest, while turning by ICTT, feed rate has the greatest effect. The study shows the initial effectiveness of ICTT in improving the quality of the machined surface and reducing the cutting temperature in the tool, which contributes to a longer tool life.