Wear reduction on cutting inserts by additional internal cooling of the cutting edge

Abstract

Modern developments of functional components result in increasing demands on new materials and their characteristics. One potential approach to raise the functional performance of components and products is the application of material combinations in the field of mechanical engineering. Due to the higher complexity of machining material combinations, the challenges concerning the cutting tool’s wear resistance and higher lifetime are increasing.The aim of this work is to demonstrate efficient machining of wire-arc-sprayed cylinder walls of engine blocks out of casted aluminium alloys. This special kind of machining application was realized by the use of thermally stabilized cutting inserts. The cutting inserts are modified with cooling channels by EDM machining in order to apply internal cooling of the tool. This results in less wear and therefore longer tool life.