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<p>Inconel 718 is a typical difficult-to-cut material with low thermal conductivity and excellent mechanical-physical properties. These characteristics result in high cutting temperatures, poor chip breakage, and rapid tool wear under conventional cooling conditions, limiting machining efficiency and process stability. The innovation in cooling technology is an effective method to improve the machinability of Inconel 718. The pulsed high-pressure jet (PHPJ) developed in our previous study has been proven to be effective to assist chip breakage and extend tool life in turning. However, the internal heat dissipation of the cutting insert was still lacking due to the concentration of cutting heat in the tool-chip contact area covered by the chip unit. To address this problem, the PHPJ-triply periodic minimal surface based thermally active toolholder (PHPJ-TAT) is proposed in this study. The cutting temperature was monitored and analyzed through statistical analysis applied to orthogonal experimental. The chip morphology and tool wear were characterized. The results showed that the cutting temperature with PHPJ-TAT was reduced by 11.3 ~ 51.9% compared with PHPJ. The contribution rate of depth of cut and feed rate to cutting temperature was reduced by 28.5% and 15.4%. The dominant inward heat dissipation mechanism along the normal direction of the rake face transitioned from a non-directional diffusion-dominated mode to a directional intensified heat conduction mode driven by a high temperature gradient. During consecutive multi-pass machining, the stepwise increase in cutting temperature induced by thermal accumulation was suppressed. The temperatures at the cutting insert and toolholder measurement points were reduced by 63.0% and 75.9%, respectively. Both the longitudinal and lateral propagation of mechanical cracks in the flank wear region were restricted under lower temperature. The tool life was extended by 52.9%. In addition, short spiral chips and C/G-type chips were generated owing to the water hammer effect. Therefore, the PHPJ-TAT could be used to improve the machinability of difficult-to-machine materials to increase the production and economic benefits.</p>

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Hybrid cooling with pulsed-high pressure jet and TPMS thermally active toolholder for turning inconel 718

  • 期刊论文

  • 发表日期：

    2026年6月24日

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  • Annan Liu,
  • Haiyang Ji,
  • Zhanqiang Liu,
  • Jinfu Zhao,
  • Xingchao Wang,
  • Ming Zhao

摘要

Inconel 718 is a typical difficult-to-cut material with low thermal conductivity and excellent mechanical-physical properties. These characteristics result in high cutting temperatures, poor chip breakage, and rapid tool wear under conventional cooling conditions, limiting machining efficiency and process stability. The innovation in cooling technology is an effective method to improve the machinability of Inconel 718. The pulsed high-pressure jet (PHPJ) developed in our previous study has been proven to be effective to assist chip breakage and extend tool life in turning. However, the internal heat dissipation of the cutting insert was still lacking due to the concentration of cutting heat in the tool-chip contact area covered by the chip unit. To address this problem, the PHPJ-triply periodic minimal surface based thermally active toolholder (PHPJ-TAT) is proposed in this study. The cutting temperature was monitored and analyzed through statistical analysis applied to orthogonal experimental. The chip morphology and tool wear were characterized. The results showed that the cutting temperature with PHPJ-TAT was reduced by 11.3 ~ 51.9% compared with PHPJ. The contribution rate of depth of cut and feed rate to cutting temperature was reduced by 28.5% and 15.4%. The dominant inward heat dissipation mechanism along the normal direction of the rake face transitioned from a non-directional diffusion-dominated mode to a directional intensified heat conduction mode driven by a high temperature gradient. During consecutive multi-pass machining, the stepwise increase in cutting temperature induced by thermal accumulation was suppressed. The temperatures at the cutting insert and toolholder measurement points were reduced by 63.0% and 75.9%, respectively. Both the longitudinal and lateral propagation of mechanical cracks in the flank wear region were restricted under lower temperature. The tool life was extended by 52.9%. In addition, short spiral chips and C/G-type chips were generated owing to the water hammer effect. Therefore, the PHPJ-TAT could be used to improve the machinability of difficult-to-machine materials to increase the production and economic benefits.