Journal of

Manufacturing and
Materials Processing

Article
Development of a New Forced Cooling Technology
Using a High-Pressure Coolant for Machining
Difficult-To-Machine Materials
Ikuo Tanabe 1, * and Hideo Hoshino 2
1 Department of Mechanical Engineering, Nagaoka University of Technology, Nagaoka 940-2188, Japan
2 Center for Integrated Technology Support, Nagaoka University of Technology, Nagaoka 940-2188, Japan;
hoshino@mech.nagaokaut.ac.jp
* Correspondence: tanabe@mech.nagaokaut.ac.jp; Tel.: +81-258-47-9727




Received: 9 May 2018; Accepted: 6 June 2018; Published: 12 June 2018


Abstract: In recent years, titanium and nickel alloys have become relevant in the production of
aeronautic and astronautic parts. Since both nickel and titanium alloys have a very small thermal
conductivity, the used tool will suffer huge damage from the heat generated during a grinding process.
Therefore, there is a requirement for a durable tool with excellent cooling capacity. In this research,
a new forced cooling technology that uses high-pressure coolant for machining difficult-to-machine
materials was developed and evaluated. Here, a through hole on the rake face near the turning tool
tip was machined by electrical discharge machining. Then, high-pressure coolant was supplied to the
turning tool from the machined hole. Several values of pressure were experimentally performed. It is
concluded from the results that the technology could effectively cool the area near the tip of a turning
tool, and that the chip was also effectively removed by the high-pressure coolant.

Keywords: forced cooling; cutting; difficult-to-machine materials; coolant

1. Introduction
Recently, titanium and nickel alloys have become relevant as they are widely used as aircraft
materials. Moreover, methods to achieve a high-precision machining of these materials have
been studied [1–3]. However, these materials have low thermal conductivity causing most of
the heat generated during machining to be conducted to the tool. This causes the vicinity of
the tool tip to become hot, leading to potential failure of the tool due to affected hardness and
mechanical strength. Thus, an effective cooling technique, such as forced cooling, against it is
desired. To this end, high-pressure-coolant-aided machining has been researched since the 1950s [4].
Moreover, optimization of conventional high-pressure coolant machining of difficult-to-machine
materials has been widely performed, and alternative cooling methods such as cryogenic machining
are currently being explored [5–9]. In the same way, extensive discussion of the usage of MQL as
an environmentally-friendly alternative to flooded coolant environments has also been presented in
compilations that are readily available [9]. From this, it has been observed that high-pressure or jet
coolant streams are an option to alter the thermal behavior near the machining zone, including both neat
oils and water-soluble oils, and provide an improved tool-life through changes in chip geometry and
breakability, friction interactions and other parameters [9]. On the other hand, supply of high-pressure
coolant has been mostly focused on positioning coolant outlets on the tool and near the machining
zone [10]. This has been observed to be optimized to alter most of the cutting zone thermal behavior
(e.g., coolant internally supplied through the tool shank straight into the cutting zone by nearby
outlets) [9,10]. It has also been presented that internally supplying coolant from the insert instead

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of just supplying it in the cutting zone vicinity could be possible during machining (i.e., parting-off
operations) [11].
Therefore, it was thought that internally supplying coolant through the insert or cutting tool
could be an alternative in heavy-duty machining conditions of hard-to-machine materials (e.g., turning
operations). In this research, a new forced cooling technology that uses high-pressure coolant internally
supplied from the cutting tool for the machining of difficult-to-machine materials during turning was
developed and evaluated. Here, for the manufacturing of said cutting tool, a through hole on the rake
face near the tip of a turning tool was machined by electrical discharge machining. Then, high-pressure
coolant was supplied to the turning tool from the machined hole. Particularly, this method proposes
an alternative to conventional methods that do not necessarily reach the tool tip-chip interface which
is the main relevant area during cutting. This method was thought to have the following benefits
by suppressing the contact of the tool rake face and the chip as shown in Figure 1: (1) suppression
of frictional heat generated between the tool rake face and chip; (2) suppression of frictional heat
conduction to the tool; and (3) efficient forced cooling near the tool tip. In order to verify this,
experimentation was carried out by mounting the proposed tool on a vertical lathe and cutting Ti6Al4V
workpieces. Here, tool temperature, tool life, and chip geometry measurements were conducted
J. Manuf. Mater. Process. 2018, 2, x FOR PEER REVIEW 2 of 7
and evaluated.

Figure 1. Schematics of the proposed forced cooling method with high-pressure coolant.
Figure 1. Schematics of the proposed forced cooling method with high-pressure coolant.

2. Evaluation of the Proposed Forced Cooling Method

Therefore, it was thought that internally supplying coolant through the insert or cutting tool
could2.1.
be Proposed
an alternative in heavy-duty
Forced Cooling Method inmachining conditions of hard-to-machine materials (e.g.
a Vertical Lathe
turning operations). In this research, a new forced cooling technology that uses high-pressure coolant
internally Turning
suppliedwas from carried out by
the cutting mounting
tool the proposed
for the machining forced cooling device
of difficult-to-machine on a vertical
materials duringlathe,
andwas
turning its cooling
developed effect
andwas evaluated.
evaluated. Here,Here,
for Figure 2 shows a photograph
the manufacturing of the
of said cutting vertical
tool, lathe and
a through
the workpiece used in the experimental section, and Table 1 shows the
hole on the rake face near the tip of a turning tool was machined by electrical discharge machining.specifications and cutting
Then, high-pressure coolant was supplied to the turning tool from the machined hole. Particularly, tool
conditions of the vertical lathe. The aforementioned machining conditions, tool temperature, and
life wereproposes
this method measured antoalternative
evaluate the to cooling effects methods
conventional of the proposed
that domachining systemreach
not necessarily by comparing
the tool dry
cutting, conventional wet cutting with high-pressure coolant, and the proposed
tip-chip interface which is the main relevant area during cutting. This method was thought to have wet cutting method.
The pressure
the following of the
benefits bycoolant to be supplied
suppressing the contact through
of the the
toolhole
rakemachined overchip
face and the the as
insert rakeinface
shown was used
Figure.
1: (1) suppression of frictional heat generated between the tool rake face and chip; (2) suppression of in
as an experimental parameter, and the conditions with the best forced cooling effect were selected
the next
frictional heatsection.
conductionHowever,to theintool;
the case
and of (3)the conventional
efficient forced cutting
coolingfluid
nearthe
thecoolant pressure
tool tip. In orderwas toset at
verify8 this,
MPa experimentation
with a flow of 0.5was `/min, which
carried outare
bythe commercially
mounting recommended
the proposed tool onparameters
a vertical for thisand
lathe turning
cutting Ti6Al4V workpieces. Here, tool temperature, tool life, and chip geometry measurements were fluid.
operation. Both wet cutting methods utilized a JIS A1 water-soluble emulsion as the cutting
Finally,
conducted theevaluated.
and workpieces used were of Ti6Al4V alloy and the inserts used were tungsten carbide inserts.
Here, the electrical discharge machining operation was ordered according to the insert material.
2. Evaluation of the Proposed Forced Cooling Method

2.1. Proposed Forced Cooling Method in a Vertical Lathe

Turning was carried out by mounting the proposed forced cooling device on a vertical lathe, and
J. Manuf. Mater. Process. 2018, 2, 39 3 of 6
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Figure 2. Vertical
Figure 2. lathe used
Vertical lathe used for
for experimentation.
experimentation.

Table 1. Specification
Table 1. Specification of
of vertical
vertical lathe
lathe and
and cutting
cutting conditions
conditions used
used in
in the
the experiment.
experiment.

Table diameter 1100 mm

Specifications of vertical

Table diameter 1100 mm

Max. turning diameter 1250 mm
Max. turning diameter 1250 mm
lathe of

Max.Max.
massmass
of workpiece 3000kgkg
vertical lathe

of workpiece 3000
Specifications

Max.Max.
cutting torque
cutting torque 10000NN·m
10,000 ·m
Vertical travel
Vertical travel of ram of ram 800 mm
800 mm
Max.Max.
feedfeedspeedspeed 500
500mm/rev
mm/rev
Main motor 30 kW
Main motor
Max. height of machine
30
3790 mm
kW
Max. height of machine
Floor space 3955 3790
× 3840mm mm
Floor space
Workpiece material 3955
Ti-6Al-4V mm
× 3840
Cutting conditions

Workpiece material
Insert type Ti-6Al-4V
Tungsten Carbide
Cutting conditions

Depth
Insert type of cut 1.0 mmCarbide
Tungsten
Depth Feed speed
of cut 0.8 1.0
mm/rev
mm
Cutting speed 60 m/min
Feed speed 0.8 mm/rev
Cooling fluid JIS A1 cutting fluid emulsion
Cutting speed
Fluid pressure 1, 60 m/min
8, 20 MPa
Cooling
Quantityfluidof flow JIS A1 cutting fluid emulsion
0.5 `/min
Fluid pressure 1, 8, 20 MPa
Quantity of flow 0.5 ℓ/min
These processing conditions were thought to be capable of reliably lifting up the generated chips
from beneath while maintaining the strength of the tool by force cooling the machining zone. This was
These
thought to processing conditions
be highly relevant were
since thought tobased
calculations be capable of reliably
on cutting lifting
theory underupthe
theaforementioned
generated chips
from beneath while maintaining the strength of the tool by force cooling
processing conditions and a feed speed of 0.8 mm/min show extreme thermal conditions the machining zone. This
[11,12].
was thought to be highly relevant since calculations based on cutting theory under the
For instance, the heat input to the tool on a dry machining operation would be 150 W and the tool
aforementioned processing conditions and a feed speed of 0.8 mm/min show extreme thermal
tip temperature would reach 2271 ◦ C in this case, which highly risks the strength integrity of the
conditions [11,12]. For instance, the heat input to the tool on a dry machining operation would be 150
tool. Moreover, if the feed speed is changed to 0.2 mm/min, the tool tip temperature would reach
W and the tool tip temperature would reach 2271 °C in this case, which highly risks the strength
1192 ◦ C. Consequently, areas of the cutting zone that might not be reachable under conventional
integrity of the tool. Moreover, if the feed speed is changed to 0.2 mm/min, the tool tip temperature
high-pressure coolant delivery techniques need to be addressed through forced cooling methods
would reach 1192 °C. Consequently, areas of the cutting zone that might not be reachable under
similar to the proposed system. The current study attempts only to study the cooling effects of a new
conventional high-pressure coolant delivery techniques need to be addressed through forced cooling
coolant delivery method and uses a conventional JIS-defined emulsion coolant. Thus, this paper does
methods similar to the proposed system. The current study attempts only to study the cooling effects
not cover highly-relevant areas for the machining of difficult-to-machine materials such as the usage
of a new coolant delivery method and uses a conventional JIS-defined emulsion coolant. Thus, this
of alternative coolants that might address thermal alleviation and equipment water-caused corrosion
paper does not cover highly-relevant areas for the machining of difficult-to-machine materials such
(e.g., strong alkaline water or microbubble-infused strong alkaline water) [13–16].
as the usage of alternative coolants that might address thermal alleviation and equipment water-
caused
2.2. Toolcorrosion (e.g.,
Temperature strong alkaline water or microbubble-infused strong alkaline water) [13–16].
Evaluation
TheTemperature
2.2. Tool Ti6Al4V workpieces
Evaluation were cut under the cutting conditions shown in Table 1, and the
tool temperature at that time was measured. Here, Figure 3a shows the temperature-measuring
The Ti6Al4V
thermocouple workpieces
located were cutofunder
in the vicinity the cutting
the cutting tool conditions
tip (Point shown in Table
A). It must 1, and that
be noted the tool
the
temperature at that time was measured. Here, Figure 3a shows the temperature-measuring
thermocouple located in the vicinity of the cutting tool tip (Point A). It must be noted that the
J. Manuf. Mater. Process. 2018, 2, 39 4 of 6
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temperature
temperature measurement
measurement in in
thethe caseofofconventional
case conventional wet
wetcutting
cuttingwas
was difficult given
difficult thatthat
given the coolant
the coolant
delivery
delivery methodmethod applied
applied coolantcoolant directly
directly onto onto this point.
this point. However,
However, it canitbecan be argued
argued that,
that, by by
comparing
comparing it to dry cutting, the proposed method forced cooling effect is large given
it to dry cutting, the proposed method forced cooling effect is large given that the temperature increase that the
temperature increase at Point A after 30 s was of about 5 °C while the cooling delivery method
at Point A after 30 s was of about 5 ◦ C while the cooling delivery method supplied coolant closer to the
supplied coolant closer to the tool tip. Figure 3b shows the results of an inverse analysis procedure
tool tip. Figure 3b shows the results of an inverse analysis procedure that used the experimental values
that used the experimental values of Figure 3a together with FEM (Finite Element Method) analysis.
of Figure 3a together
Particularly, with FEM
these results were(Finite Element
extrapolated Method)
through analysis.inverse
an FEM-based Particularly,
analysisthese results
that used twowere
extrapolated
different points (Point A and Point B) near the tool tip to estimate the temperature [17]. In the case ofPoint
through an FEM-based inverse analysis that used two different points (Point A and
B) near the tool tip
conventional to cutting,
wet estimate it the
wastemperature [17]. In the
difficult to extrapolate thecase
tooloftipconventional
temperature for wetthecutting,
reasonsit was
difficult to extrapolate
previously presented.theFrom
tool Figure
tip temperature for thetoreasons
3b, it was possible observepreviously presented.
that an increase From
in pressure Figure
leads to 3b,
it wasanpossible
improved tocooling
observe capacity.
that an increase in pressure leads to an improved cooling capacity.

Figure
Figure 3. Temperature
3. Temperature changeon
change onthe
thetool
tool using
using high-pressure
high-pressurecoolant (In(In
coolant thethe
casecase
of Ti6Al4V).
of Ti6Al4V).

2.3. Tool-life Evaluation

2.3. Tool-Life Evaluation
The tool life using the proposed forced cooling method was evaluated with the same cutting
The tool life
conditions using
(Table theinproposed
1) as the previous forced cooling
section. Here, method
the same wasthreeevaluated with the same
types of cutting—dry cutting
cutting,
conditions (Table wet
conventional 1) ascutting,
in the previous
and the section.
proposedHere,
wet the same threeanalyzed
cutting—were types of utilizing
cutting—dry Ti6Al4Vcutting,
conventional
workpieces. wetFor
cutting, and thewas
this, tool-life proposed
set to bewet cutting—were
defined analyzed
as the increase utilizing
in the tool Ti6Al4V
flank wear and workpieces.
Figure
4 shows the results of the tool life test. It must be noted that, for this research,
For this, tool-life was set to be defined as the increase in the tool flank wear and Figure 4 shows rake face wear was not the
analyzed due to the aforementioned standard definition. Here, it can be observed
results of the tool life test. It must be noted that, for this research, rake face wear was not analyzed that in the case of due
the wet cutting (20 MPa) proposed in this report, the tool life was increased by about 10.2 times when
to the aforementioned standard definition. Here, it can be observed that in the case of the wet cutting
compared to dry cutting, while the tool life was increased by about 2.7 times when compared to
(20 MPa) proposed in this report, the tool life was increased by about 10.2 times when compared to
conventional wet cutting (8 MPa). This was considered to be the result of considerably suppressing
dry cutting, while the tool life was increased by about 2.7 times when compared to conventional wet
the decrease in the hardness of the tool due to temperature rise and maintaining the tool rigidity [18].
cutting (8Finally,
MPa). This
Figure was considered
5 shows both the to be the result
generated chipofonconsiderably
the presented suppressing the decrease
turning operation and thein the
hardness of the tool due to temperature rise and maintaining the tool rigidity [18].
resultant flank tool wear at the tool-life limit of each of the selected cutting regimes. From the Figure,
Finally, Figure
it can be seen that5the
shows bothwet
proposed thecutting
generated chip on
considerably the presented
reduces turning
the flank tool operation
wear when comparedand the
with flank
resultant the other
toolcutting
wear at regimes at much
the tool-life lower
limit cutting
of each ofvolumes. Moreover,
the selected cuttingit regimes.
was observedFromthatthethe
Figure,
it canproposed tool the
be seen that did proposed
not presentwet cracks near considerably
cutting the machined reduces
hole. Onthethe flank
other tool
hand, in terms
wear whenofcompared
chip
with geometry,
the other the chip breaking
cutting regimes function
at muchoflower the conventional wet cutting
cutting volumes. methoditwas
Moreover, wasconfirmed
observed tothat
be the
present. Even with the wet cutting proposed in this report, sufficient chip breaking function was
proposed tool did not present cracks near the machined hole. On the other hand, in terms of chip
demonstrated at a 20 MPa coolant pressure. In addition, chips generated with the proposed wet
geometry, the chip breaking function of the conventional wet cutting method was confirmed to be
cutting (20 MPa) were observed to present intermittent bended sections. This was thought to be a
present. Even with the wet cutting proposed in this report, sufficient chip breaking function was
deformation of the chip above the tool rake surface caused by the high-pressure coolant supplied
demonstrated at a 20 MPa
from the machined coolant coolant
hole duringpressure. Inwhich
cutting, addition, chipshad
effectively generated with the proposed wet
a lifting effect.
cutting (20 MPa) were observed to present intermittent bended sections. This was thought to be a
deformation of the chip above the tool rake surface caused by the high-pressure coolant supplied from
the machined coolant hole during cutting, which effectively had a lifting effect.
 J. Manuf. Mater. Process. 2018, 2, 39 5 of 6
J.J. Manuf.
Manuf. Mater.
Mater. Process.
Process. 2018,
2018, 2,
2, xx FOR
FOR PEER
PEER REVIEW
REVIEW 55 of
of 66

Figure
Figure4.
Figure 4.4.Experimental
Experimentalresults
Experimental resultsof
results oftool-life
of tool-lifetest.
tool-life test.
test.

Figure5.
Figure
Figure 5. Photographsof
5.Photographs
Photographs of(a)
of (a)the
(a) thegenerated
the generatedchip
generated chipusing
chip usingmultiple
using multiplecutting
multiple cuttingmethods
cutting methodsand
methods and(b)
and (b)tool
(b) toolwear
tool wearat
wear at
at
their
their tool-life
tool-life limit
limit (Wet
(Wet cutting
cutting pressure:
pressure: 8
8 MPa,
MPa, proposed
proposed system
system pressure:
pressure: 20
20
their tool-life limit (Wet cutting pressure: 8 MPa, proposed system pressure: 20 MPa).MPa).
MPa).

3.
3.Conclusions
3. Conclusions
Conclusions
The
Theresults
The resultsof
results ofthis
of thisstudy
this studyare
study aresummarized
are summarizedas
summarized asfollows:
as follows:
follows:
(1)
(1) It
(1) ItItwas
wasconcluded
was concludedthat
concluded that aa coolant
that acoolant
coolantdelivery
delivery
delivery method
method
method that
that consists
consists
that of
consistsof machining
machining
of machining aa hole
hole at
at the
a hole at tool
the tip
tooltool
the tip
from
from which
which high-pressure
high-pressure coolant
coolant is
is supplied
supplied achieves
achieves an
an improved
improved tool-life.
tip from which high-pressure coolant is supplied achieves an improved tool-life. Here, giventool-life. Here,
Here, given
given that
that
coolant
coolant was
was directly
that coolant directly supplied
supplied
was directly between
between
supplied the tool
the the
between rake
tooltool
rake face
face
rake and
and
face andthe
the workpiece,
workpiece,heat
workpiece,
the heatgeneration
heat generation
generation
during
during the machining of difficult-to-machine materials can be suppressed to a certainextend.
during the
the machining
machining of
of difficult-to-machine
difficult-to-machine materials
materials can
can be
be suppressed
suppressed to
to aa certain
certain extend.
extend.
(2)
(2) From intermittent bended sections found in the generated chip
(2) From intermittent bended sections found in the generated chip it was concludedthe
From intermittent bended sections found in the generated chip it
it was
was concluded
concluded that
that the high-
high-
that the
pressure
pressure coolant
coolant pushes
pushes the
the chip
chip from
from the
the bottom
bottom and
and effectively
effectively reduces
reduces
high-pressure coolant pushes the chip from the bottom and effectively reduces the frictional heat
the
the frictional
frictional heat
heat
generation
generation over the rake face.
generationoveroverthe
therake
rakeface.
face.
(3)
(3) Coolant
Coolant can can be
be supplied
supplied between
between the the tool
tool rake
rake face
face and
and thethe workpiece
workpiece by by devising
devising aa high-
high-
pressure
pressure coolant
coolant delivery
delivery method
method as as observed
observed in in (1)
(1) and,
and, (2)
(2) while
while maintaining
maintaining the the tool
tool hardness
hardness
and
and integrity.
integrity.
J. Manuf. Mater. Process. 2018, 2, 39 6 of 6

(3) Coolant can be supplied between the tool rake face and the workpiece by devising a high-pressure
coolant delivery method as observed in (1) and, (2) while maintaining the tool hardness
and integrity.

Author Contributions: I.T. conceived of the presented idea. I.T. and H.H. manufactured the experimental set-up,
and experimented for evaluation of the proposed system. Two authors provided critical feedback and helped
shape the research and manuscript.
Conflicts of Interest: The authors declare no conflict of interest.

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