Abstract
Abstract The focused cutting fluid supply into the contact zone between the rake face of a cutting tool and the emerging chip, increases tool life and enables the application of higher cutting parameters for increased productivity in various machining processes. However, different workpiece materials cause different wear mechanisms on the cutting tools. As a result, the effectiveness of the focused cutting fluid supply depends on the adaption of the supply strategy to the demands of the workpiece material. Previous investigations showed that for workpiece materials, which cause abrasive wear, such as the quenched and tempered steel 42CrMo4+QT, a wide-spread supply on the rake face of the cutting tool was beneficial. In contrast, when machining titanium Ti-6AL-4V, a focused cutting fluid jet aligned to the corner of the cutting edge was beneficial in order to cool and lubricate where the elastic behavior of the titanium, caused by the low Young’s modulus, leads to severe flank wear. Hence, different workpiece materials demand different coolant nozzle designs for improved machining results. In order to achieve the individual coolant nozzle design for milling tools, additive manufacturing technologies are predestined, because they feature an enhanced freedom of design compared to conventional manufacturing technologies. However, there is little knowledge about designing cutting tools adapted for additive manufacturing in regards of coolant nozzle design. Moreover, the influence of the tool rotation on the impact point at the cutting edge is unknown. Therefore, a test bench was developed, which allowed to investigate the influence of the tool rotation in milling on the cutting fluid free jet. With this knowledge, tools can be designed to compensate the deflection of the fluid jet caused by the tool rotation. A milling tool was then additively manufactured and investigated in machining experiments with titanium Ti-6AL-4V in comparison with a conventional milling tool.
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