Developing internal cooling system in cutting tools and investigation of its effect on machining process

In this study, the effect of two different internal cooling systems on tool temperature, cutting force, feed force and tool wear has been investigated during orthogonal turning operation. The results have been compared with that of traditional (flood) cooling systems as well as dry cutting. In the experiments, an M2 type HSS cutting tool with special designed geometry has been used. Some forms of cooling channels have been machined underside of the cutting tool for the cutting fluid to circulate. Two types of fluids being water and a mixture of air-water have been experimented in the internal cooling systems. The tests were performed on two different work piece materials; CuZn37 brass and St42 steel.When machining brass, the highest cutting force was obtained from internal cooling with air-water mixture, while the lowest cutting force from flood cooling. When machining steel material, the highest and lowest cutting and feed force data were obtained from air-liquid mixture and flood cooling respectively. The highest and the lowest cutting tool temperatures have been generated when dry cutting and internal cooling with water respectively. The highest tool wear was obtained from dry cutting, while the lowest from flood cutting. Tool wear from internal cooling system has been observed to be less than that from dry cutting. With increasing feed rate, the difference in tool wear from internal cooling and flood cooling has decreased to a significant extent.