Reducing tool wear in high-speed milling of Inconel 718 by optimizing flank-face coolant direction: A CFD-supported approach toward sustainable machining

This study investigates the impact of flank face coolant nozzle orientation on tool wear suppression in the high-speed milling of Inconel 718. Preliminary dry milling of Ti-6Al-4V with a Tool-Nose-Aimed (TNA) tool revealed severe flank wear at the bolt side edge. This failure mode persisted in Inconel 718, where the TNA tool suffered from severe adhesion and brittle fracture at this location under dry, flood and all high-pressure coolant (HPC) conditions except ultra-high pressure coolant (UHPC) at 20 MPa. Thermal and Computational Fluid Dynamics (CFD) simulations diagnosed the cause: the bolt side edge is a thermal throttling zone, and the TNA's coolant jet core deviates from this critical spot. Guided by…

• BU
  Beihang University
• JS
  Japan Science and Technology Agency

  Award: JPMJSP2108